www.siemens.com/drives
Tests for induction motors
SIMOTICS
Type 1L, 1M, 1P, 1R, 1S, 1N
Reference Manual
Edition 05/2018
02.05.2018 17:22
V7.00
Legal information
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damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
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The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
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Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in
this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG
Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: Factories NMA and RHF
Ⓟ 05/2018 Subject to change
Copyright © Siemens AG 2018.
All rights reserved
Table of contents
1 Introduction...................................................................................................................................................9
2General scope of services..........................................................................................................................11
2.1 Testing equipment capacity...................................................................................................13
2.2 Tests and inspections as part of the production process.......................................................15
2.3 Function tests for the line supply according to IEC, IEEE, NEMA.........................................17
2.4 Function tests for machines connected directly to the line supply according to API 541.......20
2.5 API 541: 4th versus 5th Edition..............................................................................................23
2.6 Function tests with converter.................................................................................................25
2.7 Tests carried out on explosion-protected motors...................................................................26
2.7.1 Temperature rise test under load for all types of protection...................................................27
2.7.2 Pneumatic routine test...........................................................................................................27
2.7.3 Type tests for explosion-protected machines with type of protection "device protection
provided by pressurized enclosure "p""..................................................................................27
2.7.3.1 Pneumatic type test................................................................................................................27
2.7.3.2 Purging and dilution test as part of the type test....................................................................28
2.8 System test for variable-speed drives....................................................................................29
2.8.1 System tests for safety and reliability.....................................................................................29
2.8.2 System test............................................................................................................................29
2.8.3 Tests on explosion-protected systems...................................................................................30
2.8.4 Possible scope of a system test.............................................................................................31
2.8.5 Component test......................................................................................................................32
2.8.6 Important ordering information...............................................................................................33
2.8.7 Time required.........................................................................................................................33
3 Tests...........................................................................................................................................................35
3.1 Routine test............................................................................................................................35
3.1.1 Direct-current resistance test of the stator winding................................................................35
3.1.2 No-load test............................................................................................................................36
3.1.3 Short-circuit test.....................................................................................................................36
3.1.4 Agreement between the direction of rotation and terminal designations...............................36
3.1.5 Withstand voltage test............................................................................................................37
3.1.6 "Soft Foot test" according to API 541.....................................................................................37
3.1.7 Vibration severity measurement.............................................................................................38
3.1.8 Vibration severity measurement according to API 541..........................................................39
3.1.9 Vibration severity measurement for "Complete Test" or for "Rated Rotor Temperature
Vibration Test"........................................................................................................................43
3.1.10 Testing of accessories, integrated and mounted components...............................................45
3.1.11 Measuring the insulation resistance.......................................................................................46
3.1.12 Measurement of the polarization index..................................................................................49
3.1.13 Shaft voltage measurement...................................................................................................51
3.1.14 Bearing insulation measurement according to API 541.........................................................51
3.1.15 Air gap measurement.............................................................................................................52
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3.1.16 Runout measurement with acceptance..................................................................................52
3.1.17 Slow Roll measurement according to API 541.......................................................................53
3.1.18 Surge Comparison Test.........................................................................................................54
3.1.19 High-voltage test....................................................................................................................55
3.1.20 Voltage test of the main installation while the windings are being produced.........................56
3.1.21 Shock pulse measurement.....................................................................................................57
3.1.22 Bearing temperature rise........................................................................................................59
3.1.23 Bearing Inspection after Tests...............................................................................................60
3.1.24 Visual Bearing Checks After Tests.........................................................................................60
3.1.25 Leakage loss measurement at motors, type of protection "device protection provided by
pressurized enclosure "p"".....................................................................................................61
3.1.26 Pressure distribution measurement at motors, type of protection "device protection
provided by pressurized enclosure "p""..................................................................................62
3.1.27 Flow rate measurement and adjusting the pressurized system.............................................63
3.1.28 Leakage test for water-cooled motors....................................................................................64
3.2 Additional tests.......................................................................................................................65
3.2.1 Mechanical tests....................................................................................................................65
3.2.1.1 Overspeed test.......................................................................................................................65
3.2.1.2 Component Balance...............................................................................................................66
3.2.1.3 Residual Unbalance Verification Test....................................................................................66
3.2.1.4 Final Assembly Running Clearances / Final rotating assembly clearance data storage........67
3.2.1.5 Inspection for Cleanliness......................................................................................................67
3.2.1.6 Bearing Dimensional & Alignment Checks Before Tests.......................................................68
3.2.1.7 Bearing Dimensional & Alignment Checks After Tests..........................................................70
3.2.1.8 Vibration Recording................................................................................................................70
3.2.1.9 Vibration analysis...................................................................................................................71
3.2.1.10 Running/Vibration Tests with Coupling Half...........................................................................72
3.2.1.11 Unbalance Response Test.....................................................................................................74
3.2.1.12 Bearing Housing Natural Frequency Tests............................................................................75
3.2.1.13 Visual inspection....................................................................................................................77
3.2.1.14 Paint thickness measurement................................................................................................77
3.2.1.15 Heat exchanger performance verification test TEWAC..........................................................78
3.2.1.16 Hydrostatic test......................................................................................................................79
3.2.2 Electrical tests........................................................................................................................79
3.2.2.1 Temperature rise test under load...........................................................................................79
3.2.2.2 Testing the temperature limits of components in explosion-protected motors.......................83
3.2.2.3 Short-circuit temperature rise test for motors with type of protection Ex e.............................84
3.2.2.4 "tan δ" loss factor measurement on single coils.....................................................................86
3.2.2.5 Loss factor and capacitance measurement on the complete winding or machine.................87
3.2.2.6 Power Factor Tip-Up Test......................................................................................................90
3.2.2.7 Stator Core Test.....................................................................................................................90
3.2.2.8 Special Surge Test of Coils....................................................................................................92
3.2.2.9 Partial discharge test..............................................................................................................94
3.2.2.10 Recording the no-load characteristic and calculating losses separately................................96
3.2.2.11 Recording the short-circuit characteristic and short-circuit losses.........................................98
3.2.2.12 Plotting the load characteristic...............................................................................................99
3.2.2.13 Recording the starting torque and current............................................................................101
3.2.2.14 Recording the current and torque characteristics using a dynamometer.............................102
3.2.2.15 Calculating the efficiency from the individual losses............................................................103
3.2.2.16 Calculation of moment of inertia using the coast-down method...........................................108
3.2.2.17 Sealed Winding Conformance Test.....................................................................................109
3.2.2.18 Testing the winding insulation..............................................................................................109
Table of contents
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6Reference Manual 05/2018
3.2.3 Material Inspection...............................................................................................................110
3.2.3.1 Radiographic Test Parts.......................................................................................................111
3.2.3.2 Ultrasonic Test.....................................................................................................................112
3.2.3.3 Magnetic Particle Test Parts................................................................................................115
3.2.3.4 Liquid Penetrant Test Parts..................................................................................................116
3.2.4 Other tests............................................................................................................................117
3.2.4.1 Coordination Meeting...........................................................................................................117
3.2.4.2 "Design Review"...................................................................................................................118
3.2.4.3 Submit Test Procedures 6 Weeks Before Tests .................................................................119
3.2.4.4 Shop Inspection...................................................................................................................120
3.2.4.5 Demonstrate Accuracy of Test Equipment...........................................................................121
3.2.4.6 Stator Inspection Prior to VPI...............................................................................................122
3.2.4.7 Sound pressure level test.....................................................................................................123
3.2.4.8 Noise analysis......................................................................................................................124
3.2.4.9 Function test at the test field converter................................................................................125
3.2.4.10 Certified data prior to shipment............................................................................................126
Index.........................................................................................................................................................127
Tables
Table 2-1 Load capabilities..........................................................................................................................13
Table 2-2 Power supplies............................................................................................................................14
Table 3-1 DC test voltages to the rated motor voltages to determine the winding insulation resistance ......46
Table 3-2 DC test voltages to determine the insulation resistance of parts and components that are
either installed or mounted .........................................................................................................47
Table 3-3 Minimum value for the insulation resistance...............................................................................48
Table 3-4 temperature class / temperature rise of stator and rotor windings..............................................82
Table 3-5 Test criteria according to IEC 60034-15......................................................................................93
Table 3-6 Test criteria according to API 541 5th Edition.............................................................................93
Table 3-7 Ultrasonic probes......................................................................................................................113
Table 3-8 Permissible limit depending on the shaft diameter....................................................................114
Table 3-9 Permissible limit depending on the shaft diameter....................................................................114
Figures
Figure 2-1 Example: Overview diagram of a test configuration....................................................................13
Figure 3-1 Soft Foot Test..............................................................................................................................38
Figure 3-2 Vibration severity measuring points and directions for bearing housing vibration......................39
Figure 3-3 Vibration severity measuring equipment.....................................................................................40
Figure 3-4 ADRE 408 DSPi..........................................................................................................................40
Figure 3-5 Limit values for the vibration velocity of the bearing housing......................................................41
Figure 3-6 Limit values for shaft vibration.....................................................................................................42
Figure 3-7 Limit values for the vibration velocity of the bearing housing......................................................43
Figure 3-8 Limit values for shaft vibration.....................................................................................................43
Table of contents
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Reference Manual 05/2018 7
Figure 3-9 Circuit diagram of the insulation measurement...........................................................................47
Figure 3-10 Winding insulation resistance......................................................................................................47
Figure 3-11 Circuit diagram for the measurement of the polarization index...................................................49
Figure 3-12 Shaft voltage measurement........................................................................................................51
Figure 3-13 Example of a voltage characteristic.............................................................................................55
Figure 3-14 Example: Photograph of a sleeve bearing .................................................................................60
Figure 3-15 Wear pattern................................................................................................................................61
Figure 3-16 Photograph of the oil used..........................................................................................................61
Figure 3-17 Example of measuring strips.......................................................................................................69
Figure 3-18 Example: Frequency spectrum of a two pole 50 Hz machine.....................................................71
Figure 3-19 Example: Measurement result of dynamic unbalance test..........................................................75
Figure 3-20 Positioning the pickups at DE .....................................................................................................76
Figure 3-21 Positioning the pickups at NDE...................................................................................................76
Figure 3-22 Schematic diagram: Test setup at frequency = 50 Hz................................................................80
Figure 3-23 Schematic diagram: Test setup at frequency ≠ 50 Hz................................................................80
Figure 3-24 Example of a plot for a temperature rise test under load............................................................81
Figure 3-25 Example of a cooling-down curve, measurement for example after 50 s....................................82
Figure 3-26 Definition of the loss factor tan δ.................................................................................................86
Figure 3-27 Sketch showing the principle: Loss factor measurement at single coils......................................87
Figure 3-28 Definition of the loss factor tan δ.................................................................................................88
Figure 3-29 Loss factor measurement of complete windings or machines.....................................................89
Figure 3-30 Example of a test setup...............................................................................................................90
Figure 3-31 Stator...........................................................................................................................................91
Figure 3-32 Example of a heat image.............................................................................................................92
Figure 3-33 Surge voltage test block diagram................................................................................................93
Figure 3-34 Measuring circuit for the partial discharge measurement............................................................95
Figure 3-35 Determining the friction losses from the no-load characteristic...................................................97
Figure 3-36 Example of a load characteristic...............................................................................................100
Figure 3-37 Determining the friction losses from the no-load characteristic.................................................105
Figure 3-38 Smoothing the residual loss data..............................................................................................106
Figure 3-39 Example of a coast-down curve for speed over time................................................................108
Figure 3-40 Spraying the winding.................................................................................................................110
Figure 3-41 Example: Ultrasonic display in an A screen with flaw echoes ①.............................................113
Figure 3-42 Example of a calibration certificate............................................................................................122
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8Reference Manual 05/2018
Introduction 1
The system test facility in Nuremberg, Germany The test field in Ruhstorf, Germany
This document describes the preconditions for carrying out tests on induction motors in our
Nuremberg-Vogelweiherstrasse and Ruhstorf factories. The fulfillment of these preconditions
is the basis for achieving the smoothest possible testing process and maximum possible
customer satisfaction.
The following induction motor tests are described:
● Routine tests and inspections which are part of the normal production process
● Tests that are offered as standard
● Tests during production
Note
If the scope of testing and inspection cannot fulfill all customer requirements, please consult
your Siemens sales advisor at head office.
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Introduction
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General scope of services 2
A variable-speed drive can include the following components:
● Induction motor, synchronous motor or PEM motor with or without speed encoder
● SINAMICS drives
● Drive transformer
● Cooling unit for water-cooled drives
● Small PLCs with drive functionality.
The factory offers adapted test systems adapted to address such systems.
Note
Contact your sales person if additional components must be taken into account for your
particular project.
Scope of services offered
Unless otherwise stated in the quotation, the scope of tests ordered includes all activities,
equipment, materials and expendables required.
Additional activities, services and provisions - for example, the use of third-party converters -
must be coordinated well in advance.
The deadline and testing period stated, and the quoted cost, can be met only if all the test and
inspection procedures are clarified in detail in advance. Due to the high capacity utilization of
the associated equipment, it might not be possible to carry out individual inspections and tests
that are requested late if the planned test is already in progress.
If you have received specific requirements from your customer, please send these as soon as
possible – with the necessary key data – to the system test facility.
Test equipment
Siemens ensures the availability of the equipment required for the agreed tests and
inspections, including test couplings for load runs.
Customer couplings, coupling dummies and coupling jigs for non-cylindrical shaft extensions
are excluded.
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Sequence of a customer acceptance
A customer acceptance test is generally executed in the sequence:
1. Installation and commissioning of the components before the customer arrives.
2. Kickoff with presentation of the test schedule and discussion of individual steps in the
acceptance test workflow.
3. Execution of the tests according to the test schedule
4. Discussion of the test results
5. Preparation of test documentation for the customer.
The test documentation is created before or after the customer leaves depending on the
scope of testing and the time schedule.
Components provided by customer
Components provided by the customer must be available in plenty of time so that tests can be
carried out on time. The factory has no access to components, which are not part of the scope
of supply of PD LD. This also applies to components ordered from other Siemens' Groups.
The technical data for these components is required at the latest eight weeks before the start
of the acceptance test, e.g.:
● Dimensions
● Weights
● Energy Requirement
● Interfaces
See also
Testing equipment capacity (Page 13)
General scope of services
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12 Reference Manual 05/2018
2.1 Testing equipment capacity
The technical data of the test systems and equipment are listed in the following tables. If this
available capacity does not meet your requirements, please consult your Siemens sales
person. The following possibilities are available:
● Equivalent loading and substitution techniques and mathematical calculation of projected
performance data
● The machine(s) can be tested in the Berlin plant
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Figure 2-1 Example: Overview diagram of a test configuration
Possibilities available in our Nuremberg factory
Table 2-1 Load capabilities
Speed [rpm] Torque [Nm] Power [kW] Max. shaft height [mm]
0 ... 1500
1500 ... 2100
31830 max. 0 ... 5000
5000 max.
710
710
0 ... 3000
3000 ... 4200
15915 max. 0 ... 5000
5000 max.
710
710
General scope of services
2.1 Testing equipment capacity
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Reference Manual 05/2018 13
0 ... 600
600 ... 800
79577 max. 0 ... 5000
5000 max.
1100
1100
0 ... 6000
6000 ... 8000
1591 max. 0 ... 1000
1000 max.
500
500
Table 2-2 Power supplies
Type Voltage [kV] Taps [%] Power [kVA or kW]
Direct 20
Medium-voltage transformer 1.73 / 3 / 3.4 / 6
5 / 10 / 13.8
±13
±13
6000
6000
Medium-voltage transformer 1.73 / 3 / 3.4 / 6
5 / 10
-9 / +16
-9 / +16
3600
3600
Low-voltage transformer Up to 0.7 3150
SINAMICS LV converter 0.7 4500
Possibilities available in our Ruhstorf factory
Shaft height [mm] Max. 1000
Torque [Nm] Max. 45 000
Power [KW] Max. 4800
Frequency [Hz] 30 ... 60
Voltage levels [V] Current [A]
15000 Max. 220
11000 Max. 330
6600 Max. 570
3000 Max. 1000
1000 Max. 3200
Special features:
● Testing submersible motors in water tanks that can be heated
● Load noise measurements in an acoustic measuring chamber up to approximately 3 MW
- or a machine weight of up to 16 tons
● System tests with drive components from all of the usual manufacturers
● Tests performed according to customer specifications, especially in the oil and gas industry
Instrumentation
When requested, with the test, persons witnessing the test are provided with a list of the
measuring equipment and devices.
General scope of services
2.1 Testing equipment capacity
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2.2 Tests and inspections as part of the production process
Transformers
The transformer manufacturer carries out routine checks on the transformer according to
IEC 76 / VDE 0532. The following is checked/tested:
● Insulation test
● Vector group
● Transformation ratio
● Resistances
● No-load test
● Short-circuit test
Converter
The routine test for converters include the following:
● Visual inspection
● High-voltage insulation test according to EN 60146-1 and EN 50178
● Function test, e.g. auxiliary voltages, software, firmware
● U/f test
Options that have been ordered are taken into consideration for the specified tests. Where
relevant, individual tests will also be performed for specific options.
Motors
The routine test for motors in accordance with IEC / EN 60034-1 includes the following:
● Determining the stator winding resistance
● Testing the insulation resistance of the stator winding
● No-load tests
● Short-circuit test
● Phase sequence and direction of rotation
● Testing optional built-on/mounted equipment
● Withstand voltage test
Note
No inspection/testing of converter
None of the tests specified for the transformers and motors will be performed on the converter.
The factory certificates for components supplied by LD will be discussed with the customer at
the kickoff presentation.
General scope of services
2.2 Tests and inspections as part of the production process
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Converters and motors are already subject to a routine test by the manufacturer as part of the
quality assurance program. Consequently, the routine test is not repeated for the acceptance
test, unless it has been explicitly ordered.
Note
Test documents are created automatically and so not signed.
General scope of services
2.2 Tests and inspections as part of the production process
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2.3 Function tests for the line supply according to IEC, IEEE, NEMA
The machine is subject to a comprehensive function test . The machine in the context of the
system capacity is operated with the rated data for this type and all machine-specific
characteristic data determined.
The function test is performed in accordance with IEC/EN 60034-1/-29, based on ANSI/
NEMA MG-1 and IEEE 112 method A, B, B1 or E1.
Optionally, function tests are performed in the presence of the customer. Certain function tests
in no-load operation are obligatory, and are always performed. IEC 60034-1 links them with a
routine test.
Routine test
The routine test is necessary to check the correct functioning of a machine. Reference
variables are provided by a motor of the same type, which was subject to comprehensive
function tests ("type test").
Reference variables are available for 50 Hz and 60 Hz in certain voltage versions for each
motor type. The variables measured during a routine test are converted over to the voltage
and frequency of the reference variables and then compared.
The machine is released if the converted measured variables lie within the tolerance range.
In the event of deviations outside the tolerance level, the cause of this is determined in a
General scope of services
2.3 Function tests for the line supply according to IEC, IEEE, NEMA
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Reference Manual 05/2018 17
separate investigation and, if necessary, rectified. The results of the routine test are
summarized in the routine test certificate.
Routine test Order codes
Without the customer
present
With the customer
present
● Measurement of the insulation resistance Risol
● DC resistance test of the stator winding
● Testing of accessories, integrated and mounted
components
● Agreement between the direction of rotation and
terminal designations
● Vibration severity measurement 2
● No-load test (P0 + I0)
● Short-circuit test
● Shaft voltage measurement 3
● Surge voltage test 4
● Surge pulse measurement 5
● High-voltage test
● Voltage test of the main insulation while the
windings are being produced
F001
F01
1F00 is part of the scope of the standard test.
2Not included in the minimum scope of the routine test according to IEC 60034-1, however, it is still
performed.
3Only carried out for motors with non-insulated bearings.
4If a surge voltage test has already been carried out, then 80 % of the test voltage is used for testing.
5Only for motors with roller bearings and measuring nipple
Function tests under load (combination test F82 / F83)
You can individually ordered the following function tests, but also as combination test with
order codes F82 (without the customer being present) or F83 (with the customer present).
Function tests under load Order codes
Without the customer
present (F82)
With the customer
present (F83)
Temperature rise test under load F04 F05
Recording the no-load characteristic and determining
iron (core) and no-load losses (no load operation)
F14 F15
Plotting the short-circuit characteristic and calculating
the short-circuit losses
F16 F17
General scope of services
2.3 Function tests for the line supply according to IEC, IEEE, NEMA
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Recording the load characteristic F18 F19
Calculating the efficiency from the individual losses 6F20 F21
6"Calculating the efficiency from the individual losses" (F20/F21) can only be ordered in conjunction
with "Temperature rise test under load" (F04/F05), "Recording the no-load characteristic and
determining the iron (core) and no-load losses" (F14/F15) and "Recording the load characteristic"
(F18/F19).
Additional tests
The following additional tests can be individually ordered.
Function tests Order codes
Without the customer
present
With the customer
present
"tan δ" loss factor measurement on single coils F22 F23
Loss factor measurement "tan δ" on the installed stator
winding in the test bay
F26 -
Noise measurement (no-load operation) F28 F29
Measuring the cooling air flow (no-load operation) F30 F31
Plotting the current and torque characteristics using a
dynamometer (load)
F34 F35
Calculation of moment of inertia using the coast-down
method
F36 F37
Overspeed test F38 F39
Sealed Winding Conformance Test according to NEMA F42 F43
Partial-discharge measurement F46 -
Measurement of locked-rotor torque and locked-rotor
current
F52 F53
Measuring the insulation resistance and polarization in‐
dex
F54 F55
Vibration analysis (no-load operation) F58 F59
Impulse or AC voltage test on two single coils F60 F61
Noise analysis (no-load operation) F62 F63
Sleeve bearing inspection - F67
Runout measurement 7- F71
7Is always measured when producing machines with sleeve bearings with shaft vibration measuring
systems.
General scope of services
2.3 Function tests for the line supply according to IEC, IEEE, NEMA
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2.4 Function tests for machines connected directly to the line supply
according to API 541
Optionally, the machine is subject to a comprehensive function test according to API 541 .
Routine test according to API
The following tests are part of the routine tests according to API. You can order the tests as
"Required", "Witnessed" or "Observed".
Function tests of the routine test Order codes
Re‐
quired
Wit‐
nessed
Ob‐
served
● Calculation of the short-circuit current 1
● DC resistance test of the stator winding
● Testing of accessories, integrated and mounted components
● Agreement between the direction of rotation and terminal
designations
● Bearing temperature rise test
● Vibration severity measurement after a temperature rise test under
load 2
● No-load test (P0 + I0)
● Short-circuit test
● Shaft voltage measurement 3
● Withstand voltage test on stator winding 4
● Measuring the insulation resistance and polarization index
● Visual sleeve bearing inspection after the electrical tests
● Bearing insulation measurement 5
● Air gap measurement 5
● Slow roll measurement
F100
F101
F102
1The calculation is made in the order processing phase when generating the electrical documentation.
2For machines with sleeve bearings equipped with shaft vibration measuring systems, the runout is
measured while the rotor is being produced.
3Only carried out for motors with non-insulated bearings.
4If a surge voltage test has already been carried out, then 80 % of the test voltage is used for testing.
5These tests are part of the quality assurance process.
General scope of services
2.4 Function tests for machines connected directly to the line supply according to API 541
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Complete Test according to API (F154, F155, F156)
The tests of the complete test can be ordered individually and also as combination test using
order code F154 ("Required"), F155 ("Witnessed") or F156 ("Observed").
Tests included in the "Complete Test"Order codes
Without the
customer
present
(F154)
With the cus‐
tomer
present
(F155, F156)
Plotting the no-load characteristic and calculating the iron and no load
losses
F14 F15
Temperature rise test under load F04 F05
Vibration measurement under load 6- -
Plotting the short-circuit characteristic and calculating the short-circuit
losses
F16 F17
Recording the load characteristic under load F18 F19
Calculating the efficiency from the individual losses according to
IEC 60034-2-1 / IEEE 112 7
F20 F21
Recording the current and torque characteristics using a dynamometer
under load
F34 F35
Noise measurement according to IEC under no load conditions F28 F29
6Vibration acceptance values only for no load operation.
7"Calculating the efficiency from the individual losses" (F20/F21) can only be ordered in conjunction
with "Temperature rise test under load" (F04/F05), "Recording the no-load characteristic and
determining the iron (core) and no-load losses" (F14/F15) and "Recording the load characteristic"
(F18/F19).
Tests according to API during production
You can order the tests as "Required", "Witnessed" or "Observed".
Tests according to API during production Order codes
Re‐
quired
Wit‐
nessed
Ob‐
served
Surge Comparison Test F120 F121 F122
Component Balance F126 - -
Final Balance F129 F130 F131
Stator Inspection Prior to VPI F139 F140 F141
Final Assembly Running Clearances / Final rotating assembly clear‐
ance data storage
F172 - -
Runout measurement with acceptance - F71 -
Special surge test of coils F123 F124 F125
Stator Core Test F117 F118 F119
Residual Unbalance Verification Test F132 F133 F134
Sealed Winding Comformance Test according to NEMA F142 F143 F144
Overspeed Test - - F138
General scope of services
2.4 Function tests for machines connected directly to the line supply according to API 541
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Reference Manual 05/2018 21
Bearing Dimensional & Alignment Checks Before Tests F148 F149 F150
Bearing Dimensional & Alignment Checks After Tests F160 - -
Additional tests according to API
You can optionally order additional tests according to API
Function tests Order codes
Re‐
quired
Wit‐
nessed
Ob‐
served
Final Inspection - F03 -
Design Review F103 - -
Coordination Meeting - F104 -
Lateral Critical Speed Analysis F105 - -
Shop inspection F106 - -
Submit Test procedures 6 weeks before Tests F107 - -
Inspection for Cleanliness F108 F109 F110
Heat exchanger performance verification test TEWAC 8F111 F112 F113
Demonstrate Accuracy of Test Equipment F114 F115 F116
Running Test with Coupling Half / Vibration Test with Coupling Half
under no-load conditions
F135 F136 F137
Power Factor Tip-Up Test 9F145 - -
Vibration Recording F151 F152 F153
Sound pressure level test F157 F158 F159
Unbalance Response F166 F167 F168
Bearing Housing Natural Frequency Test F169 F170 F171
Hydrostatic Test F175 - -
Certified data prior to shipment F176 - -
All required test and inspection equipment F177 - -
Rated Rotor Temperature Vibration Test under load 10 F191 F192 F193
Material inspections
● Radiographic Test Parts F178 - -
● Ultrasonic Test Parts F181 - -
● Ultrasonic Inspection of Shaft Forging F184 - -
● Magnetic Particle Test Parts F185 F186 F187
● Liquid Penetrant Test Parts F188 F189 F190
8Only together with "Complete Test", and under test facility/test field conditions
9Equivalent to F26
10 Individual tests are part of the Complete Test and do not have to be ordered in addition to the
Complete Test.
General scope of services
2.4 Function tests for machines connected directly to the line supply according to API 541
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22 Reference Manual 05/2018
2.5 API 541: 4th versus 5th Edition
The paragraphs of API 541 differ between the 4th und 5th editions.
Test API 4th edition API 5th edition
Routine Test 4.3.2 6.3.2
Coordination Meeting - 8.2
Design Review 6.2.1.4 8.4
Torsional Analysis 2.4.6.2.4 4.4.6.2.2
Lateral Critical Speed Analysis 2.4.6.2.1 4.4.6.2.1 /
8.6.2b
Shop Inspection 4.1.1 -
Submit Test Procedures 6 Weeks Before Tests 4.3.1.5 6.3.1.4
Inspection for Cleanliness 4.2.3.2 / 4.2.3.3 6.2.3.3
Observance of Assembly / Dismantling 4.3.1.1 -
Demonstrate Accuracy of Test Equipment 4.3.1.14 6.3.1.15
Stator Core Test 4.3.4.1 6.3.4.1
Surge Comparison Test 4.3.4.2 6.3.4.2
Special Surge Test of Coils 4.3.4.2.1 6.3.4.2.1
Component Balance 2.4.6.3.1 -
Final Balance 4.3.1.6.1 -
Residual Unbalance Verification Test 2.4.6.3.6 /
6.2.5.1a
4.4.6.3.4
Balance Check with Half Coupling 2.4.6.3.3 -
Running Tests with Coupling Half / Vibration Test with Coupling Half 2.4.6.3.3 /
4.3.1.6
4.4.9.4 / 6.3.1.5
Stator Inspection Prior to VPI 4.3.4.5 6.3.4.5
Sealed Winding Conformance Test 4.3.4.4 6.3.4.4
Power Factor Tip-Up Test 4.3.4.3 6.3.4.3
Partial Discharge test - 6.3.4.6)
Bearing Dimensional & Alignment Checks Before Tests 4.3.2.1j 6.3.2.1k
Vibration Recording 4.3.3.12 -
Purchaser supplied vibration monitoring / recording - 6.3.3.7
Complete Test 4.3.5.1.1 6.3.5.1.1
● Efficiency 4.3.5.1.1a 6.3.5.1.1
● Locked Rotor 4.3.5.1.1b 6.3.5.1.1
● Heat Run 4.3.5.1.1e 6.3.5.1.1
● Sound Pressure Level Test 4.3.5.1.1g 6.3.5.1.1
Bearing Dimensional & Alignment Checks After Tests 4.3.2.1k 6.3.2.1l
DC High-Potential Test 4.3.5.1.2 6.3.5.1.2
Unbalance Response Test 4.3.5.3 6.3.5.3
Bearing Housing Natural Frequency Tests 4.3.5.4 6.3.5.4.1
Heat exchanger performance verification test TEWAC - 6.3.5.5
Overspeed test - 6.3.5.6 / 4.1.5
General scope of services
2.5 API 541: 4th versus 5th Edition
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Reference Manual 05/2018 23
Test API 4th edition API 5th edition
Final Assembly Running Clearances / Final rotating assembly clear‐
ance data storage
4.2.1.1e 6.2.1.1e
Material Inspection 4.2.2 6.2.2
● Radiographic Test Parts 4.2.2.2 6.2.2.2
● Ultrasonic Test Parts 4.2.2.3 6.2.2.3.2
● Ultrasonic Inspection of Shaft Forging 4.2.2.3.1 4.4.5.1.8 /
6.2.3.1
● Magnetic Particle Test Parts 4.2.2.4. 6.2.2.4
● Liquid Penetrant Test Parts 4.2.2.5. 6.2.2.5
● Hydrostatic test - 6.2.2.6
Rated Rotor Temperature Vibration Test 4.3.5.2.1 6.3.5.2.1
Bearing Inspection After Tests 4.3.2.1i 6.3.2.1j
Certified data prior to shipment - 8.6.2a
All required test and inspection equipment - 6.1.4
General scope of services
2.5 API 541: 4th versus 5th Edition
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24 Reference Manual 05/2018
2.6 Function tests with converter
Function tests with converter Order codes
Without the
customer
present
With the cus‐
tomer
present
Function test with test field converter F74 F75
System test with the customer's converter - F97
See also
Function test at the test field converter (Page 125)
System test for variable-speed drives (Page 29)
General scope of services
2.6 Function tests with converter
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2.7 Tests carried out on explosion-protected motors
Electrical machines are used in the widest range of designs and power ratings in hazardous
zones. As a result of the many motor versions, when testing and certifying there are an
extremely wide range of requirements relating to explosion protection. The basic requirements
relating to electrical machines are specified in the series of IEC / EN 60034-1 standards.
Additional requirements for various types of protection are described in the series of
IEC / EN 60079-ff standards.
The mechanical version of the machine is the basis for certifying explosion-protected drives.
The approval is summarized in the form of a mechanical test report. The test report includes
results of the various tests according to the standards listed above, e.g. material properties of
the individual components, IP degree of protection test, ... . The test report is generally
accepted by a testing body. At the time of the type test, the acceptance has normally been
completed.
Only the aspects of the electrical-pneumatic measurements are discussed in the following
chapter.
The type of protection defines which aspects of explosion protection are tested at the machine.
The type of protection is reflected in the Ex marking:
● A machine with "Increased safety "e"" type of protection is tested to ensure that the
respective temperature class is complied with. This means, in normal operation, or in the
case of a locked rotor, it is not permissible that the defined temperature limits are exceeded
at any part of the machine.
● A machine with "Increased safety "ec"" type of protection is tested to ensure that the
appropriate temperature class is complied with. Contrary to type of protection "Increased
safety", compliance with the temperature class is only tested under normal operating
conditions.
● Machines with type of protection "Pressurized enclosure "p"" are subject to specific
pneumatic tests. Based on a thermal test, it is verified that the appropriate temperature
class is complied with outside the pressurized enclosure.
● A machine with "flameproof enclosure "d"" type of protection is tested to ensure that the
appropriate temperature class is complied with under normal operating conditions.
General scope of services
2.7 Tests carried out on explosion-protected motors
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2.7.1 Temperature rise test under load for all types of protection
The temperature rise test under load is most important test for all types of protection. During
the test, the temperature class of the complete machine is verified. The following is tested:
Compliance with the upper temperature limits for the winding, seals, cable and conductor
branches/connections, maximum operating temperature for mounted devices etc.
●
Motors destined for Zone 1 - with the following types of protection - are tested as standard.
– "Device protection provided by pressurized enclosure "p""
– "Increased safety "e""
– "Flameproof enclosure "d""
● Motors destined for Zone 2 – with the following types of protection - are optionally tested.
– "Increased safety "ec""
See also
Temperature rise test under load (Page 79)
2.7.2 Pneumatic routine test
The following tests are part of the routine test for motors, type of protection "device protection
provided by pressurized enclosure "p"".
● Leakage loss measurement at motors, type of protection "device protection provided by
pressurized enclosure "p"" (Page 61)
● Pressure distribution measurement at motors, type of protection "device protection provided
by pressurized enclosure "p"". (Page 62)
● Flow rate measurement and adjusting the pressurized system (Page 63)
2.7.3 Type tests for explosion-protected machines with type of protection "device
protection provided by pressurized enclosure "p""
2.7.3.1 Pneumatic type test
The following is tested for each new electrical design of motors with type of protection "device
protection provided by pressurized enclosure "p"":
● The level of leakage at the maximum operating pressure is measured.
Leakage loss measurement at motors, type of protection "device protection provided by
pressurized enclosure "p"" (Page 61)
● When purging with the set flow rate, the pressure in the enclosure must not fall below the
minimum pressure level.
General scope of services
2.7 Tests carried out on explosion-protected motors
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Reference Manual 05/2018 27
● At all measurement locations, it is not permissible that the minimum pressure falls below a
value of 50 Pa.
Pressure distribution measurement at motors, type of protection "device protection provided
by pressurized enclosure "p"". (Page 62)
● The parameters of the pressurizing system must correspond to the EU type examination
certificate regarding the following data:
– Purge time
– Purge volumes
– Differential pressure at the start of purging
– Maximum and minimum pressure
– ...
Flow rate measurement and adjusting the pressurized system (Page 63)
2.7.3.2 Purging and dilution test as part of the type test
For motors with type of protection "device protection provided by pressurized enclosure "p"",
the minimum purge rate and minimum purging time are defined as part of the type test. These
values are dependent on the type of construction and cooling method. The maximum gas
concentrations according to IEC / EN 60079‑2 Appendix A.2 apply as test criteria.
The purging and dilution test is carried out by the certification body, e.g. Physikalisch-
Technischen Bundesanstalt (PTB) corresponding to the restrictions and corresponding to
IEC / EN 60079‑2 Annex A.
General scope of services
2.7 Tests carried out on explosion-protected motors
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28 Reference Manual 05/2018
2.8 System test for variable-speed drives
2.8.1 System tests for safety and reliability
For a system test, complete drive systems are installed on the test stand. Once systems have
been tested in this way, they operate extremely safely and reliably in processing and
manufacturing industries.
The load simulation in the system test bays check/test the interaction between all the system's
components, e.g.:
● Motors
● Converter
● Gear unit
● Brakes
● All other drive components
The following is examined here:
● Standard operating ranges, e.g.
– 4-Quadrant operation
– Dynamic and regenerative braking
– Undervoltage and overvoltage monitoring
– Temperature rise in braking resistors
● Extreme operating situations and faults, e.g.:
– Abrupt load change
– Load shedding
– Shock load
2.8.2 System test
The basis for a system test is generally a temperature rise test under load. All other listed tests
are supplements to the temperature rise test under load. If your customer has specified
something else, then please contact your sales person.
The following sequence is only an example; on a case-for-case basis, the sequence and scope
of the system test is defined together with the customer.
General scope of services
2.8 System test for variable-speed drives
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Temperature rise test under load during the system test
1. Recording the electric data of the motor in a cold state
– Stator winding resistance
– Stator winding insulation resistance (optional)
2. The machine coupled to the load machine (dynamometer) is if possible operated with the
converter at rated speed and rated torque until it reaches its steady-state temperature, i.e.
the motor temperature changes by less than 2 K within one hour. If a speed range is
specified, then the speed at which the highest temperature rise is expected is selected.
For example, the following parameters are continuously recorded during the measurement:
– Primary current, primary voltage, primary power and primary power factor of the
transformer (if one is being used)
– Converter output frequency
– Motor current, motor voltage
– Motor speed
– Torque and power at the motor shaft
– Motor enclosure temperature (optional)
– Motor winding temperature
The winding temperature is only measured if there is a winding Pt100.
– Motor bearing temperature
– For machines with air/water cooler, which are equipped with Pt100 elements at the air
intake and discharge, then these temperatures are also recorded.
3. Measuring the winding temperatures
– The resistance when warm is measured.
– The cooling-down curve is recorded by measuring the stator winding resistance. The
average motor temperature rise at the instant of shutdown is derived from this curve.
2.8.3 Tests on explosion-protected systems
There are various requirements laid down in standards for drive systems, which must be used
in hazardous zones.
"Increased safety" "Flameproof enclosure" "Pressurized enclo‐
sure"
"Non-sparking"
EN 60079-0
Standards EN 60079-7 EN 60079-1 EN 60079-2 EN 60079-7
System test re‐
quired?
Yes No No Yes or an alternative
calculation
Certification with in‐
dividual converter?
Required Not required Not required Required
Type of certification EU type examination certificate of the nominated body, e.g. PTB EU declaration of con‐
formity
General scope of services
2.8 System test for variable-speed drives
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30 Reference Manual 05/2018
2.8.4 Possible scope of a system test
A part of these tests are already included in the manufacturing process and are carried out
within the framework of the quality assurance program. These tests are no longer performed
for the acceptance test unless they have been explicitly ordered.
Tests that you can order for system acceptance - in addition to the temperature rise test under
load - are listed in the following. The time required for these must be taken into consideration
for the system acceptance tests.
Load points and determining the system efficiency
1. Temperature rise test under load
2. The following parameters are measured at different speeds at each load point:
– Primary current, primary voltage, primary power and primary power factor of the
transformer (if one is being used)
– Converter output frequency
– Motor current, motor voltage
– Motor speed
– Torque and power at the motor shaft
3. The overall system efficiency is then calculated from this data.
Measurement of harmonics
1. This measurement is either made at the input terminals of the converter power unit or at
the primary side of the converter transformer (if one is being used).
Note
The measured values are only valid for the line supply conditions in the test bay at the time
of the measurement. These values do not necessarily apply at the customer site.
HV insulation test/insulation test
The high-voltage test/insulation test is already part of the routine test for motor and converter.
The work required to prepare, conduct and retest the converter cannot be practically included
in the time required for the system test. During the system test, it is not possible to additionally
test the converter insulation. The high voltage test at the converter must be separately ordered,
and this is conducted before the system acceptance test.
Function test of the drive system
Key functions of the drive system are verified during this test.
● EMERGENCY STOP
● Individual, selected remote operation signals are tested
● Individual, selected fault and alarm messages/signals are tested
General scope of services
2.8 System test for variable-speed drives
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Reference Manual 05/2018 31
● Circuit breakers are manually opened to simulate failure of auxiliary systems
Visual inspection
● Visual inspection of the converter and motor
● Where relevant, visual inspection of the transformer
Noise measurement at the motor
1. The motor is operated at the converter and at rated speed without any load.
2. The sound pressure level of the machine is recorded at defined measuring points. The
sound pressure level is calculated on an A-weighted basis.
Vibration test at the motor
1. The motor is operated at the converter and at rated speed without any load.
2. The vibration velocities are measured for the rated voltage and frequency at the bearing
housing.
3. For sleeve bearings, the shaft vibration is also measured if the appropriate transducer is
mounted.
2.8.5 Component test
The system components are individually tested before the system test (F97).
Component Tests
Transformer
(according to IEC 76 /
VDE 0532)
● Insulation test (applied and induced high-voltage)
● Vector group
● Transformation ratio
● Resistances
● No-load measurements
● Short-circuit test
General scope of services
2.8 System test for variable-speed drives
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32 Reference Manual 05/2018
Converter ● High-voltage insulation test according to EN 60146-1 and EN 50178
● Visual inspection
● Function inspection (auxiliary supplies, software, firmware)
● U/f test
Motor *
(according to IEC 34-1)
● Determining the stator winding resistance
● Stator insulation test
● No-load measurements
● Short-circuit measurements
● Phase sequence
● Testing optional built-on/mounted equipment
* For F74/F75, only the motor is checked.
2.8.6 Important ordering information
In the order, state in plain text whether a system acceptance test is required, witnessed by the
customer or somebody that the customer mandates to do this.
Example
● Definition of the system to be tested, e.g. system acceptance test for a high-voltage motor
and a SINAMICS GM drive system with 2500 kW rating, including transformer
The catalog data of all components is required, e.g. ordering data (=MRPD)
● The scope of the system acceptance test, e.g. temperature rise test under load and
definition of the load points
Based on this data, a test plan is drawn-up and sent to the orderer.
2.8.7 Time required
This information is only intended to provide you with a rough idea regarding the time required.
The actual time required depends on the configuration and the test scope.
Preparing for the
acceptance test
Conducting Disassembling
the system
Ordering deadlines
Low voltage 2 ... 3 days 1 ... 2 days 1 ... 2 days At least four months
before the accept‐
ance date
Medium voltage 1 ... 2 weeks 2 ... 3 days 1 ... 3 days
General scope of services
2.8 System test for variable-speed drives
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General scope of services
2.8 System test for variable-speed drives
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Tests 3
3.1 Routine test
Each motor is subject to a routine test according to IEC 60034-1. Additional checks and tests
are performed within the scope of quality assurance. The sequence of the subsequently
described tests is random and is not fixed.
3.1.1 Direct-current resistance test of the stator winding
Fundamentals
The DC resistance test is used to check the stator winding. If a temperature rise test under
load has been ordered, then this test is also used to determine the average (mean) winding
temperature. It is checked that the internal specifications for the DC winding resistance and
the winding design are complied with.
Test procedure
1. The DC resistance between the two phases is measured using an ohmmeter.
$:989
$:989
Star connection Delta connection
2. This measurement is repeated for all phase combinations.
3. The measured values are scaled to a 20 °C reference temperature.
Result
The directly measured DC resistances, scaled to 20 °C, are listed in the test report. The
measured values displayed are compared with the specified target values.
The test is successfully completed if the measured values remain within the tolerance
specifications. The measured values and test results are documented in a 3.1 certificate – or
in the case that the customer has ordered the acceptance test, in a 3.2 certificate.
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Reference Manual 05/2018 35
3.1.2 No-load test
Fundamentals
The no-load losses and the no-load current are determined at rated voltage and rated speed.
Test procedure
1. The resistance when cold is measured.
2. The motor is operated at rated speed and rated voltage. The no-load losses are recorded.
The values of the measuring points are documented in the test report.
Result
The no-load losses at the measuring point and at 100 % rated voltage are compared with the
internal test specifications. The test is confirmed in a 3.1 certificate – or in the case that the
customer has ordered the acceptance test, in a 3.2 certificate.
3.1.3 Short-circuit test
Fundamentals
The short-circuit test is used to check the rotor, the rotor winding and the current symmetry.
Test procedure
1. With the rotor mechanically locked, the motor is fed with a variable voltage at the rated
frequency and the stator current measured. The voltage amplitude at the motor (short-circuit
voltage) is varied until the rated current is obtained.
2. Alternatively, the direction of rotation is reversed while the motor is operating; the stator
current is measured at the zero crossover.
The measured values are listed in the form of a table in the measurement report.
Result
The short-circuit voltage is compared with the internal test specifications and the current
symmetry is monitored in the various phases. The successful test is confirmed in a 3.1
certificate – or in the case that the customer has ordered the acceptance test, in a 3.2 certificate.
3.1.4 Agreement between the direction of rotation and terminal designations
Fundamentals
Checking that the terminal designation and the direction of rotation match ensures that the
direction of rotation of a correctly commissioned motor corresponds to what has been specified.
Tests
3.1 Routine test
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36 Reference Manual 05/2018
Test procedure
1. The designations on the mains supply cables and terminals are checked. When viewed
from the drive side, the direction of rotation is defined as follows:
– L1 L2 L3 at U V W produces a clockwise direction of rotation.
– L1 L2 L3 at V U W produces a counter-clockwise direction of rotation.
2. The motor is connected corresponding to the specified direction of rotation.
3. The direction of rotation is then checked when the motor starts.
Result
The test is successfully completed if the direction of rotation matches what has been specified.
The test is confirmed in a 3.1 certificate – or in the case that the customer has ordered the
acceptance test, in a 3.2 certificate.
3.1.5 Withstand voltage test
Fundamentals
With the withstand voltage test, the winding insulation of the active components under voltage
are tested with respect to ground potential and also with respect to one another. These active
components include, for example individual winding phases, temperature sensors, anti-
condensation heating etc.
Test procedure
1. The test voltage is applied between the winding phases and between winding phase and
ground potential.
The duration of the withstand voltage test is 1 min. The amplitude of the withstand voltage
at the various tested motor parts is specified in the measurement report.
Result
The successful completion of the test is confirmed in the measurement report. The test values
are documented in a 3.1 certificate – or in the case that the customer has ordered the
acceptance test, in a 3.2 certificate.
3.1.6 "Soft Foot test" according to API 541
Fundamentals
● API 4th edition 4.3.1.15
● API 5th edition 6.3.1.16
Tests
3.1 Routine test
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Reference Manual 05/2018 37
For all vibration tests (shaft and housing vibration), the motor must be mounted and clamped
to a test grating, completely free from any distortion. The test can only be completed on type
IM B3 motors and is completed at a standstill.
The "Soft Foot Test" is used to determine whether the motor is mounted and installed to
measure vibrations in accordance with the requirements.
Test procedure
1. The machine is positioned on the test grating.
2. A feeler gauge is used to test how much underlay is required for a uniform placement of all
machine feet. The measured differences between the machine feet are compensated using
shims.
3. The machine is attached to the test frame with all its feet. The mounting is attached in close
proximity to the relevant foot. The clamping elements should be positioned as horizontally
as possible and cover slightly more than half the foot width or depth on the surface of the
foot.
4. The fastening at each foot is loosened individually. The degree of the remaining distortion
of the machine is then measured. The distortion must not exceed a limit value. The result
is documented internally.
Figure 3-1 Soft Foot Test
Result
The machine is installed and mounted according to the requirements of "Soft Foot".
3.1.7 Vibration severity measurement
Fundamentals
The vibration severity measurement is conducted according to IEC / EN 60034-14.
The vibration severity limits must be complied with to prevent damage to parts of the plant and
system and the motor itself as a result of increased levels of vibration.
Tests
3.1 Routine test
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38 Reference Manual 05/2018
Test procedure
After the bearings have been run in, the vibration speeds at the rated voltage and rated
frequency are measured in the horizontal, vertical and axial direction to the bearing housings
at the drive end and non-drive end.
Measuring points Drive end Non-drive end
Horizontal ① ④
Vertical ② ⑤
Axial ③ ⑥
+ 45° ⑦ ⑨
- 45° ⑧ ⑩
Figure 3-2 Vibration severity measuring points and directions for bearing housing vibration
For sleeve bearings, at measuring points ⑦ to ⑩ the shaft vibration is also measured if the
appropriate transducer is mounted.
Result
The results of the vibration severity measurement are compared with the specifications in
IEC / EN 60034-14 and are documented together with the operating conditions in a 3.1
certificate, or if a customer acceptance test has been ordered, in a 3.2 certificate.
3.1.8 Vibration severity measurement according to API 541
Fundamentals
● API 4th edition: 4.3.3.2
● API 5th edition: 6.3.3.4
The vibration limit values according to API 541 are only applicable for machines, whose
bearings have reached their steady-state operating temperature. This is the reason that before
every vibration measurement, a bearing temperature rise test (Page 59) is conducted.
Bearing housing vibration is measured in the horizontal, vertical and axial directions at the
bearing housing of roller and sleeve bearings.
For motors with sleeve bearings, shaft vibration is measured in the radial direction using
contactless eddy current pickups if measuring pickups are mounted or have been prepared.
If there are no shaft vibration pickups, only the vibration of the bearing housing is measured.
Tests
3.1 Routine test
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Reference Manual 05/2018 39
Measuring points Drive end Non-drive end
Horizontal ① ④
Vertical ② ⑤
Axial ③ ⑥
+ 45° ⑦ ⑨
- 45° ⑧ ⑩
Bearing housing vibration levels for roller bearings ①...⑥, shaft vibration levels for sleeve bearings
⑦ to ⑩
Figure 3-3 Vibration severity measuring equipment
Test equipment
Vibration pickups and measuring signal transducers mounted on the motor are used if they
are compatible with the equipment in the test bay. Alternatively, sensors available in the test
bay are used. The test bay sensors fulfill the accuracy requirements laid down by API 670.
Vibration levels are recorded using a data acquisition system, and analyzed. The data
acquisition system complies with all criteria laid down in API 541 4th edition 4.3.3.7 or
5th edition 6.3.3.7.
For example, the "Dynamic Signal Processing Instrument" ADRE 408 DSPi is used together
with the "Sxp" software platform.
Figure 3-4 ADRE 408 DSPi
After prior consultation, customers can use their own measuring technology to acquire data.
In this case, the following topics are coordinated together with the customer:
● List of all used measuring instruments.
● List of all measurements to be performed using customer instrumentation. This means that
the time frame can be estimated.
Tests
3.1 Routine test
SIMOTICS 1L, 1M, 1P, 1R, 1S, 1N
40 Reference Manual 05/2018
● The measuring instrumentation must comply with the local safety regulations; for example,
the measuring cables must be long enough so that the measurement can be performed
outside the hazardous area.
● The instrumentation must be compatible with the test setup.
Note
Siemens (the test bay) must be informed of this at least four weeks before the start of testing.
Test procedure
1. A bearing temperature-rise run is performed.
2. The unfiltered and filtered radial and axial vibration, voltage, frequency and the bearing
temperature are recorded. The measurement takes at least 15 minutes.
Result
The maximum value of the vibration variable, measured during the motor test run, is compared
with the limit value.
The test is successfully completed if the limit values are not exceeded. The results are
displayed in the form of a trend plot. As documentation of the test result, a 3.1 certificate is
issued, or for acceptance tests witnessed by the customer, a 3.2 certificate is issued.
Bearing housing vibration
At speeds above 1000 rpm, the bearing housing vibration limit is 2.54 mm/s (0-pk).
9LEUDWLRQYHORFLW\SHDNYDOXHLQV
8QILOWHUHG6SHHGPLQ
Figure 3-5 Limit values for the vibration velocity of the bearing housing
Shaft vibration
At speeds up to 5300 rpm, the shaft vibration limit is 38.1 mm/s (p-p).
Tests
3.1 Routine test
SIMOTICS 1L, 1M, 1P, 1R, 1S, 1N
Reference Manual 05/2018 41
6SHHGPLQ
9LEUDWLRQGLVSODFHPHQWPLOVSS
8QILOWHUHG
Figure 3-6 Limit values for shaft vibration
Result
The maximum value of the vibration variable, measured during the motor test run, is compared
with the limit value.
The test is successfully completed if the limit values are not exceeded. The results are
displayed in the form of a trend plot. As documentation of the test result, a 3.1 certificate is
issued, or for acceptance tests witnessed by the customer, a 3.2 certificate is issued.
Bearing housing vibration
At speeds above 1000 rpm, the bearing housing vibration limit is 2.54 mm/s (0-pk). Limit values
for other speeds are calculated using the following formula:
1SPPV
Tests
3.1 Routine test
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42 Reference Manual 05/2018
9LEUDWLRQYHORFLW\SHDNYDOXHPPVS
6SHHGUSP8QILOWHUHG
Figure 3-7 Limit values for the vibration velocity of the bearing housing
Shaft vibration
At speeds up to 5300 rpm, the shaft vibration limit is 38.1 mm/s (p-p). Limit values for other
speeds are calculated using the following formula:
wPSS1
8QILOWHUHG
9LEUDWLRQDPSOLWXGHwPSS
6SHHGUSP
Figure 3-8 Limit values for shaft vibration
3.1.9 Vibration severity measurement for "Complete Test" or for "Rated Rotor
Temperature Vibration Test"
Fundamentals
● API 4th edition: 4.3.5.2.1
● API 5th edition: 6.3.5.2.1
Tests
3.1 Routine test
SIMOTICS 1L, 1M, 1P, 1R, 1S, 1N
Reference Manual 05/2018 43
The vibration severity measurement is part of the "Complete Test" and corresponds to the
"Rated Rotor Temperature Vibration Test" according to API (Page 39).
The motor is mounted on steel blocks to adapt the motor shaft height to the dynamometer.
This type of mounting does not correspond to "Soft Feet" mounting. Coupling the motor to the
load can result in changes to the vibrational behavior. This is mainly caused by components
that are required for the coupling, e.g.
● Test coupling
● Multiple-disk couplings for two-pole motors – or an articulated shaft for motors with four
poles and higher
● Gearbox and dynamometer
This additional vibration is specific to the test bay and for customers is available in another
form and magnitude at the installation site.
Depending on the test field equipment and the power range, deviations from what is specified
in API can occur. These deviations are communicated and coordinated with the customer in
advance.
Test procedure
1. A temperature rise test under load (Page 79) is performed.
2. The motor is shut down.
3. The machine is quickly decoupled and the tested coupling is removed.
4. The machine is rigidly mounted corresponding to the "Soft Foot test".
5. Bearing housing and the relative shaft vibration is measured under no load at the rated
voltage and rated frequency.
Result
Only the vibration values, which are measured according to Point 5, are used to evaluate the
measurement.
The measured values and test result are documented in a 3.1 certificate – or in the case that
the customer has ordered the acceptance test, in a 3.2 certificate.
NOTICE
Overall vibration
In accordance with API 4th edition 4.3.3.9, the unfiltered and filtered vibration (direct value;
1x and 2x components) are measured over the entire duration of the temperature rise test
under load:
● Figure 3-5 Limit values for the vibration velocity of the bearing housing (Page 41)
● Figure 3-6 Limit values for shaft vibration (Page 42)
The overall vibration, as the sum of these vibration components, can exceed the value laid
down in API 541.
Tests
3.1 Routine test
SIMOTICS 1L, 1M, 1P, 1R, 1S, 1N
44 Reference Manual 05/2018
See also
Vibration severity measurement according to API 541 (Page 39)
NOTICE
Overall vibration
In accordance with API 5th edition 6.3.3.1.1.e, the unfiltered and filtered vibration (direct
value; 1x and 2x components) are measured over the entire duration of the temperature rise
test under load:
● Figure 3-7 Limit values for the vibration velocity of the bearing housing (Page 43)
● Figure 3-8 Limit values for shaft vibration (Page 43)
The overall vibration, as the sum of these vibration components, can exceed the value laid
down in API 541.
See also
Vibration severity measurement according to API 541 (Page 39)
3.1.10 Testing of accessories, integrated and mounted components
Fundamentals
The function of accessories as well as installed and mounted components is checked and
ensured.
Test procedure
1. For temperature sensors integrated in the windings and for anti-condensation heating
systems, the resistance and the temperature are measured. After this, the insulation
resistance is determined corresponding to Table (Page 48). The voltage test is with respect
to ground potential with 1500 V~.
2. For temperature sensors for bearing and air temperatures, the resistance and the insulation
resistance are measured.
3. Other accessories – such as vibration sensors and pulse encoders – are tested, if required,
corresponding to the particular Operating Instructions.
Result
If the accessories, installed and mounted components match the specifications, then the test
is successfully completed. The test is confirmed in a 3.1 certificate – or in the case that the
customer has ordered the acceptance test, in a 3.2 certificate.
See also
Measuring the insulation resistance (Page 46)
Tests
3.1 Routine test
SIMOTICS 1L, 1M, 1P, 1R, 1S, 1N
Reference Manual 05/2018 45
3.1.11 Measuring the insulation resistance
Fundamentals
The tests essentially correlate with the recommendations of IEEE 43-2013. While assembling
the machines, tests are carried out at the components or at the complete machine in the scope
of the routine or type test – and during the product lifecycle within the scope of checking the
condition of the insulation as part of a diagnostics routine.
The insulation state of the winding insulation and the electrically insulated mounted and
installed components are tested with respect to ground. If required, the insulation state is also
checked with respect to one another to ensure that the defined minimum requirements are
complied with.
As a consequence, in addition to the withstand voltage test, it has been proven that the winding
insulation has been perfectly implemented and functions as it should with respect to ground.
The insulation resistance is measured at the stator winding or at the complete machine. The
resistance of the winding insulation is measured with respect to ground or the winding phases
and winding elements. The insulation resistance is a measure for the insulating property
(dielectric strength) of the insulation of live components with respect to ground or with respect
to one another.
Measuring the insulation resistance allows the following conclusions to be drawn:
● The specified production processes have been complied with, e.g. hardening of the resin
impregnation
● Absorption of moisture, moisture content of the insulation
● Conductive pollution/dirt on the surfaces, e.g. creepage paths
● Age-related changes, e.g. the formation of creepage paths
The measurement results are influenced by the following factors:
● Machine size regarding the stator winding
● Insulation design
● Materials used
The following table shows the insulated components of a machine – and the tests and
measuring voltages preferably to be applied. The measuring voltages can vary slightly across
factories.
Table 3-1 DC test voltages to the rated motor voltages to determine the winding insulation resistance
Rated voltage UB of the motor [V] DC test voltage [V]
IEEE 43 API 541 4 th API 5 th
UB < 1000 500 1000 500
1000 ≤ UB ≤ 2299 500 ... 1000
1000
2300 ≤ UB ≤ 2500
2500
2501 ≤ UB ≤ 3999 1000 ... 2500
2500
4000 ≤ UB ≤ 5000
5000
5001 ≤ UB ≤ 12000 2500 ... 5000
5000
UB > 12000 5000 ... 10 000
Tests
3.1 Routine test
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Table 3-2 DC test voltages to determine the insulation resistance of parts and components that are
either installed or mounted
Insulated component DC test voltages [V]
Winding temperature sensors 500 ... 1000
Anti-condensation heating to ground/to the winding UN to
1000 V
500
Insulated bearings 100 ... 250
Other insulated components 500
The resistance of the winding insulation is measured with respect to ground potential. If the
neutral point is accessible or open, then the insulation resistance of the winding phases or the
winding elements with respect to one another is measured.
,QVXODWLRQPHWHU:LQGLQJ0വ
Figure 3-9 Circuit diagram of the insulation measurement
ˊ˖
Figure 3-10 Winding insulation resistance
Tests
3.1 Routine test
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For windings and mounted & installed components, minimum insulation resistances for new
and operationally aged windings are defined according to the following table.
Table 3-3 Minimum value for the insulation resistance
Insulated component Minimum values for operationally-aged ma‐
chines
[MΩ]
Minimum values for new ma‐
chines
[MΩ]
IEEE 43-2000 Siemens / Large Drives
40 °C 25 °C 25 °C 40 °C 25 °C
Stator winding UN < 1000 V * 5 20 20 25 100
Stator winding UN ≥ 1000 V 100 300 300 500 1500
Winding temperature sensor to ground - - 500 - 2500
Anti-condensation heating to ground - - 1 - 5
Anti-condensation heating to winding UN up to
1000 V
- - 20 - 100
Insulated bearings - - 1 - 1
Other insulated components - - 100 - 500
* The values apply for the complete winding with respect to ground. Twice the minimum values apply to the measurement of
individual phases
The minimum values for the insulation resistance of new insulation/windings are valid for the
measuring voltages specified in the table.
The minimum values apply for the following conditions:
● Measuring temperature of 25 °C ±5 °C or 40 °C ±5 °C
● Relative humidity up to 70 %
For different measurement and/or object temperatures, the measured values are converted to
a reference temperature of preferably 40 °C using the following equations from IEEE 43.
RC = KT · RTRCInsulation resistance converted to a 40 °C reference temperature
(1) kTTemperature coefficient according to (2)
RTMeasured insulation resistance for measurement/object temper‐
ature T
KT = 0.5 (40-T)/10 40 Reference temperature
(2) 10 Halving / doubling of the insulation resistance with 10 K
T Measurement/object temperature
Test equipment
The measurement is taken with an insulation meter or a highly stable DC source and a µA
meter.
Tests
3.1 Routine test
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Test procedure
The test is performed before the machine is switched on for the first time. The insulation
resistance is preferably determined at the voltages specified in the table above. For large
machines, the winding phases are preferably measured individually. In this case, an accessible
and open neutral point is required.
1. The measurement is made between the winding and ground. Windings, integrated winding
temperature sensors and possibly other mounted and installed components are connected
to ground.
2. The measuring voltages correspond to the table above or to the applicable specification.
– For the type test, the values are read off after 1 min.
– For the routine test, the test is ended when the minimum value is reached.
3. After completion of the measurement, the windings are discharged.
Result
For windings and mounted & installed components, minimum insulation resistances are
defined according to the following table. The test is successfully completed if these values are
reached. A lower insulation resistance can be obtained at higher air humidities or higher
temperatures.
The test is confirmed in a 3.1 certificate – or in the case that the customer has ordered the
acceptance test, in a 3.2 certificate.
3.1.12 Measurement of the polarization index
Fundamentals
Measurement is preferably carried out corresponding to the recommendations of
IEEE 43-2013 (see Table 3-3 Minimum value for the insulation resistance (Page 48)) – or
according to what is laid down in the applicable specification.
The polarization index (PI) indicates the time-dependent polarization processes in the
insulation. The polarization index is formed from the time characteristic of the insulation
resistance or the insulation currents. The polarization index indicates the moisture content and
degree of pollution/dirt of the winding insulation.
Figure 3-11 Circuit diagram for the measurement of the polarization index
Tests
3.1 Routine test
SIMOTICS 1L, 1M, 1P, 1R, 1S, 1N
Reference Manual 05/2018 49
Test equipment
● Insulation meter with a highly stable DC current source and a μA meter
● Insulation meter with integrated automatic determination of the polarization index
Procedure when testing the winding
1. Just the same as for the insulation resistance measurement, the measuring device is
connected between the winding and/or winding element/phase to be measured and ground
(laminated core, enclosure, shaft for rotor windings).
2. When automatically determining the polarization index, the measurement is performed in
the "Polarization index" mode. The required measuring voltage is set corresponding to
Table 3-3 Minimum value for the insulation resistance (Page 48) or the specification that
applies.
3. The polarization index is calculated from the ratio between the measured insulation
resistance after 10 min and after 1 min – or the inverse ratio of the currents. For devices
where the polarization index is automatically determined, the polarization index is
automatically displayed after a measuring time of 10 min.
Result
The measured values must, as a minimum, correspond to the requirements shown in the first
line of the Table 3-3 Minimum value for the insulation resistance (Page 48). For lower PI values,
the overall diagnostic data of the winding is included in the evaluation along with the possibly
required measures.
The measured values are assessed using the following table.
R(10 min) / R(1 min) Assessment
≥2 ● Insulation in good condition
<2 ● Insulation resistance >5 GΩ → test successfully completed and OK
(API 4th Edition/IEEE 43)
● Insulation resistance >100 GΩ → test successfully completed and OK
(API 5th Edition)
The measured values and test results are documented in a 3.1 certificate – or in the case that
the customer has ordered the acceptance test, in a 3.2 certificate.
See also
Measuring the insulation resistance (Page 46)
According to API, the polarization index is measured before and after the high-voltage test.
Tests
3.1 Routine test
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3.1.13 Shaft voltage measurement
Fundamentals
The shaft voltage is measured. Excessively high shaft voltages can cause arcing across the
film of grease or oil on the bearings. Circulating currents can result, which damage the bearings.
Note
● According to IEC, the shaft voltage is only measured if none of the bearings are insulated.
● According to API, the shaft voltage is also measured if the bearings are insulated.
Test procedure
1. The measurement is made between the shaft ends.
P9
Figure 3-12 Shaft voltage measurement
Result
If the limits according to the test plan are exceeded, then a bearing (non-drive end) is insulated.
The measured values and test result are documented in a 3.1 certificate – or in the case that
the customer has ordered the acceptance test, in a 3.2 certificate.
3.1.14 Bearing insulation measurement according to API 541
Fundamentals
Excessively high shaft voltages can cause arcing across the film of grease or oil on the
bearings. Circulating currents can result, which damage the bearings. The bearing insulation
resistance measurement checks as to whether the electrical insulation is high enough to
prevent circulating currents.
Test equipment
An insulation resistance measuring device is used as the test device.
Tests
3.1 Routine test
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Reference Manual 05/2018 51
Test procedure
Production internally carries out the measurement.
● For rolling bearings, the insulation resistance at the enclosure is measured using a test
voltage of 100 V or 250 V, for example. The measurement is carried out after assembling
the insulated bearing before attaching the bearing shield.
● The insulation resistance of sleeve bearings is measured after the installation of the shaft
vibration sensors.
Result
The test has been successfully completed if the measured resistance of the bearing insulation
is at least 1 MΩ. The test result is documented internally. It is not possible that the customer
witnesses this test.
3.1.15 Air gap measurement
Fundamentals
Checking the air gap checks as to whether the electrical and mechanical specifications have
been complied with.
Note
This test involves an indirect measurement: The air gap is calculated based on the difference
between the measured internal stator diameter and the measured external rotor diameter.
Calculation
The calculation is carried out and documented by production.
Result
The calculation is documented internally. A report is generated if requested by the customer
(optional order). It is not possible that the customer witnesses this test.
3.1.16 Runout measurement with acceptance
Fundamentals
For this measurement, the mechanical and electrical Runout of the complete rotor is
determined in accordance with API 4.3.3.1.
The "Runout" is all of the metallurgical inhomogeneities in the shaft surface, local remaining
magnetism and mechanical irregularity of a shaft that are not generated by vibrations.
Measuring the Runout is only possible for motors that have been designed and built for
contactless measurement of the shaft vibration levels. The Runout value is measured in µm.
Tests
3.1 Routine test
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Runout measuring procedure
1. Electrical and mechanical Runout are measured in the balancing machine in so-called V-
prisms with a contactless pickup (transducer) and a dial gauge at the center of the
measuring track on the shaft over one complete revolution (360°). The following values are
measured for each measuring track:
– The mechanical Runout is measured using a probe.
– The total Runout is measured as a total of the mechanical and electrical runout using
an eddy current pickup.
2. The measurement is repeated if the start and end values of the measurement series are
not this same.
Result
On the measuring surface for the radial vibration monitoring, the combined electrical and
mechanical Runout value must not exceed the following values:
● The values specified in IEC 60034-14
● In accordance with API 541, 25% of the maximum permissible unfiltered peak-to-peak value
of the shaft vibration.
See also
Vibration severity measurement according to API 541 (Page 39)
3.1.17 Slow Roll measurement according to API 541
Fundamentals
The Slow Roll measurement in the complete machine serves as a comparative measurement
for the runout measurement of the rotor. The result allows a quantitative assessment of the
total shaft vibration in operation to be made. Only machines with sleeve bearings are tested,
and with sensors for the shaft vibration measurement.
Test procedure
1. At the complete machine, the shaft vibration is measured while machine coasts down with
an axially fixed rotor in the speed range from 300 rpm to 200 rpm.
Result
Maximum value of the shaft vibration values are 30% of the maximum permissible unfiltered
peak-to-peak value of the shaft vibration.
The measured values and test results are documented in a 3.1 certificate – or in the case that
the customer has ordered the acceptance test, in a 3.2 certificate.
Tests
3.1 Routine test
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Reference Manual 05/2018 53
See also
Vibration severity measurement according to API 541 (Page 39)
3.1.18 Surge Comparison Test
Fundamentals
● API 4th edition: 4.3.4.2
● API 5th edition: 6.3.4.2
The winding test corresponds to the coil comparison test according to API ("Surge Comparison
Test").
The test ensures that the coils, used for the winding, have the required withstand voltage
between the winding turns or layers.
The winding turns and layers are tested with the impulse voltage. With the impulse voltage,
with a rise time in the vicinity of < 1 µs, generated by discharging a capacitor, the coil impedance
generates a voltage drop across the coil being tested. The voltage is approximately linearly
distributed over the winding turns within the coil. The winding turn or layer voltage obtained is
approximately the impulse voltage applied across the coil divided by the winding turns/number
of layers of the coil.
The test can also be carried out on complete windings. As a result of the non-uniform voltage
distribution and the higher cost for fault detection and location, this test is mainly used during
the production of round wire windings and when diagnosing winding problems in the service
environment.
Tests
3.1 Routine test
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54 Reference Manual 05/2018
Test procedure
The test is carried out after inserting the coils in the laminated core before connecting up the
individual coils.
1. The impulse voltage is connected to one end of the coil, and the other end of the coil is
connected to the ground potential of the impulse generator. Generally, the laminated core
is not grounded, to reduce the voltage at the main insulation of the coils.
2. Depending on the test equipment being used, either two coils are simultaneously tested in
a comparative test or, at one coil a reference voltage characteristic is recorded. This is then
saved and used as a basis to compare the other coils to be tested.
3. All of the winding coils are tested using the specified voltage. Each coil is tested with a
minimum of five voltage impulses. The voltage amplitude depends on the machine type
(coil design). This can be identified by reviewing the relevant winding data taken from the
test plan.
Figure 3-13 Example of a voltage characteristic
For amplitude or frequency deviations from the reference signal or between two signals with
respect to one another, which exceed the tolerance range, the cause is clarified. Depending
on the fault profile, additional tests may be required. The fault is resolved or the coil involved
is replaced.
Result
The test has been successfully completed if the voltage characteristics are congruent in the
defined tolerance range; this means that there are no significant deviations with respect to the
reference signal or between one another.
A successfully completed test is confirmed in a 3.1 certificate – or in the case that the customer
has ordered the acceptance test, in a 3.2 certificate.
3.1.19 High-voltage test
Fundamentals
As part of the routine test, the high-voltage test is carried out according to IEC 60034-1 with
2 · UN + 1000 V~ 50 Hz for 1 min. The winding with respect to ground and, if possible, also the
phases are tested with respect to one another.
Tests
3.1 Routine test
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Reference Manual 05/2018 55
The test ensures the minimum withstand voltage of the winding insulation with respect to
ground (enclosure, laminated core) - and where relevant, the winding phases with respect to
one another. This method is also called "power-frequency withstand voltage test".
Test procedure
1. The test voltage is applied at rated voltages from > 1 kV between the winding and ground,
and if possible, also between the winding phases.
The test voltage must be at the line frequency and should be a sinusoidal is possible.
2. The test voltage is maintained for 1 minutes. It is not permissible that any arcing or sparking
occurs.
When checking the machine/winding again, e.g. within the context of the type or acceptance
test, only 80 % of the test voltage is applied, corresponding to what is laid down in the standard.
For machines with rated voltages of > 6 kV, a DC voltage test at 1.7x of the rms value of the
test AC voltage can be alternatively used if high rating AC voltage test equipment is not
available.
Result
The value of the test voltage is documented in the routine test certificate or in the acceptance
test certificate. This test is always successful, as faulty windings are withdrawn from the
system.
A successfully completed test is confirmed in a 3.1 certificate – or in the case that the customer
has ordered the acceptance test, in a 3.2 certificate.
3.1.20 Voltage test of the main installation while the windings are being produced
Fundamentals
After the coils have been inserted in the laminated core, and before impregnating the windings,
the insulation of the winding to ground potential (laminated core) is tested. If possible, the
insulation between the winding phases is tested using high voltage. This tests that the main
coil insulation has no faults.
Test equipment
High-voltage source with charging capacity for the winding size to be tested
Test procedure
1. The coils are all connected with one another or per phase. This is realized depending on
the point in time in production through the winding connection.
2. The high voltage is applied to the coils/winding and the laminated core grounded.
For the inter-phase test, the phases that are not being tested are connected to ground
potential (laminated core).
Tests
3.1 Routine test
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56 Reference Manual 05/2018
3. The voltage is increased from zero up to the target value and is maintained for at least
1 min.
The amplitude of the test voltage depends on the insulation system being used and is
defined internally.
4. The tested winding is then short-circuited, grounded and discharged.
Result
The test has been successfully completed, if, within the test time, no sparking or arcing
occurred, and the current did not significantly increase. In the case of a fault, the coil involved
is localized and replaced, or a new insulation applied.
The test result is documented internally.
3.1.21 Shock pulse measurement
Fundamentals
Structure-born transient noise is generated when the rolling elements roll on the raceway if
the surfaces of the raceway and rolling elements are rough or damaged. This structure-born
sound is propagated to the surrounding material, and is detected by an acceleration sensor
(SPM transducer). The SPM probes convert these pulses into electrical impulses, whose
amplitude is proportional to the shock velocity.
The following variables are measured:
● Carpet value dBcSV: The noise, i.e. the many small pulses, provides information about the
lubricating film thickness in the load zone. An increasing trend indicates a reduction in the
lubricating film thickness in the load zone.
● Maximum value dBmSV: The highest pulse measured during the measuring time. Pulses
such as these occur for significant damage or irregularities of the raceway or rolling
elements.
dB stands for decibels, c for Carpet, m for maximum, SV for "Shock Value" (not scaled).
A reliable statement about the condition of the roller bearings cannot be made after just one
single measurement. To do this, several measured values, sensed at intervals during the
operating time, are required. The trend characteristic of these measured values provides
information about the change to the roller bearing and lubrication state - and the remaining
service life.
Empirical values are defined for non-standardized shock pulses. These empirical values apply
as acceptance criterion for the shock pulse measurement.
Customers can use the values from the shock pulse measurement in the routine test as
reference value to identify pending bearing damage, if the measured values for dBSV are scaled.
Tests
3.1 Routine test
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Reference Manual 05/2018 57
VHFRQGVG%LG%PG%1G%FG%69
Initial value dBi depends on Umin and the shaft diameter. dBN is the unit for the scaled
measurement.
Test equipment
Surge impulse tester, e.g. T2000 from SPM Instrument
Tests
3.1 Routine test
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58 Reference Manual 05/2018
Test procedure
1. The machine is mounted corresponding to its type of construction, and is operated,
uncoupled under no-load conditions with its rated voltage and frequency.
2. The SPM probe is attached to an SPM nipple mounted at the motor. The measurement
starts.
3. Values dBcSV and dBmSV are measured and documented.
Result
The measured values displayed are compared with the specified target values. The test has
been successfully completed if the measured values remain below the specified limits. The
measured values and test result are documented in a 3.1 certificate – or in the case that the
customer has ordered the acceptance test, in a 3.2 certificate.
3.1.22 Bearing temperature rise
Fundamentals
● API 4th edition: 4.3.2.1h
● API 5th edition: 6.3.2.1h
The bearing temperature rise test serves to prove that in no-load operation, the bearings do
not leak, do not emit unusual noise or manifest increased vibration or temperature levels. The
bearing temperature rise test is the initial basis for almost all vibration tests according to API.
With the exception of the "Unbalance Response Tests", the bearing temperature rise test is
carried out before starting all additional no load vibration measurements described in API.
Before the bearing temperature rise test, the motor is mounted on a solid foundation in
accordance with "Soft Foot", as vibration is immediately measured at the end of the bearing
temperature rise test.
Test procedure
1. The machine is rigidly mounted corresponding to the "Soft Foot test".
2. The machine is operated under no load conditions until the bearing temperature stabilizes,
and it is then operated for an additional hour at a constant bearing temperature. "Constant
bearing temperature" means a maximum temperature change of 1 K/30 min.
3. The following temperatures are continuously recorded during the measurement:
– Bearing temperature on the drive and non-drive end
– Housing temperature
– Ambient temperature
– Additional installed and mounted temperature sensors
– Only for sleeve bearings: Oil temperature, with oil input and outlet temperature as the
reference temperature
Tests
3.1 Routine test
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Result
The measured values are documented in a 3.1 certificate – or in the case that the customer
has ordered the acceptance test, in a 3.2 certificate.
3.1.23 Bearing Inspection after Tests
Fundamentals
During the visual bearing inspection after the electrical tests, the following components of the
sleeve bearing undergo a visual inspection for damage including dents, lead-in grooves,
material displacements, etc.:
Test procedure
After the electrical tests - and after the sleeve bearings have cooled down - the following
components are visually inspected in production.
● Removed bearing shells
● Shaft bearings including the bearing shoulders
● Bearing seals
Result
The report contains photos of the contact surfaces of the bearing shells and shaft bearings.
The test result is documented in a 3.1 certificate – or in the case that the customer has ordered
the acceptance test, in a 3.2 certificate.
Figure 3-14 Example: Photograph of a sleeve bearing
3.1.24 Visual Bearing Checks After Tests
Fundamentals
● API 4th edition: 4.3.2.1i
● API 5th edition: 6.3.2.1j
During the visual bearing inspection a check is made to determine whether the wear pattern
corresponds to at least 80 % of the possible contact surface of the rotor in the bearing shell.
Tests
3.1 Routine test
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The wear pattern is documented.
Figure 3-15 Wear pattern
Depending on the factory involved, the report also contains photos of the oil used during the
electrical tests.
Figure 3-16 Photograph of the oil used
3.1.25 Leakage loss measurement at motors, type of protection "device protection
provided by pressurized enclosure "p""
Fundamentals
The test is conducted according to IEC / EN 60079-2 and the technical documentation of the
pressurized system.
Using compressed air, the machine is tested to ensure that it has no leaks, and any leakage
losses are measured.
Tests
3.1 Routine test
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Test equipment
● Manometer
● Pressurized air flow meter
● Thermometer
Test procedure
The test is performed in the same standard way for all pressurized systems, independent of
the manufacturer.
1. A compressed air connection with compressed air meter is connected at an access point
on the motor enclosure.
2. The manometer is connected to the motor enclosure.
3. The pressurized system is closed and sealed. This therefore avoids leaks as a result of the
pressurized system.
4. The pressure is increased to the operating pressure and maintained at this level.
Measurements are made at the maximum speed and when the motor is stationary.
The machine is investigated for any leaks once the operating pressure has been reached.
– Acoustically by listening for a hissing noise
– Optically using mist-generating or fog generating equipment
– Sensory, for example a cold air flow in contact with the skin, e.g. back of your hand
– Leaks are sealed.
The amount of air fed in is measured over a defined period of time.
5. The ratio of standstill time to operating time is calculated based on the two measurements.
6. Optionally, when the motor is undergoing final checks before shipping, and after painting,
leakage is again measured at standstill.
To determine the final leakage in operation, the value last measured is multiplied by the
calculated ratio of standstill time to operating time. This value is stamped on the motor
rating plate.
Result
An internal test report is generated.
3.1.26 Pressure distribution measurement at motors, type of protection "device
protection provided by pressurized enclosure "p"".
Fundamentals
According to IEC / EN 60079-2, it is not permissible that the minimum pressure of 50 Pa inside
the motor is fallen below. The minimum pressure at the monitoring location is determined using
this measurement.
Tests
3.1 Routine test
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Test equipment
● Manometer
● Compressed air meter or flow rate measuring instrument
● Thermometer
Test procedure
1. The pressure sensors are mounted on the motor at the specified measuring locations. The
measuring locations differ between machine versions, and for example, are located in the
bearing shield at the DE or NDE, the top-mounted cooler, terminal box etc.
2. Measurements are taken in the following operating states, and the pressure documented
at the individual measuring locations:
– For line operation
- Motor operating at rated speed without the pressurized air supply connected
- Motor operating at rated speed or maximum speed and operating pressure (optional)
– For motors fed from converters (converter operation)
- One series of measurements at the lower speed limit and one at the upper speed limit
As the pressure levels are measured at any value between the minimum and maximum
pressure, the results are interpolated up or down to the minimum pressure at the monitoring
location. The measured values are converted into relative pressure values. The reference
pressure is the pressure outside the motor enclosure. For air-cooled motors with mounted
cooler, the reference pressure is the back pressure in the cooler tubes.
Result
The test result is documented in a 3.1 certificate – or in the case that the customer has ordered
the acceptance test, in a 3.2 certificate.
3.1.27 Flow rate measurement and adjusting the pressurized system
Fundamentals
The test is conducted according to IEC / EN 60079-2 and the technical documentation of the
pressurized system.
The air flow of the pressurized system is checked. The minimum flow of inert gas is necessary
in order to guarantee safe operation.
Test equipment
● Manometer
● Compressed air meter or flow rate measuring instrument
● Thermometer
Tests
3.1 Routine test
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Test procedure
1. The manometer is connected to the motor enclosure through the pressurized system to
document the pressure inside the motor enclosure during purging.
2. The pressurized system is ready to function is connected to the pressurized air supply.
3. With the pressurized air supply connected, purging is started. The purge time is set to 5 min
or an empirical value.
4. Using the purge air valve connected to the pressurizing system, the purge air quantity is
increased until the required purge air quantity is reached at the purge air output. The purge
airflow is adjusted to the purge quantity specified for the particular motor type.
5. The purge airflow is sensed at the output valve of the pressurized system. This is achieved
with a tube, with a defined inner diameter, that is installed at the purge air output. The
measuring device is adjusted to the inner diameter. The purge airflow is read out at the
device and recorded.
6. Alternatively, the purge airflow is sensed at the input valve of the pressurized system at the
pressurized air meter. The purge airflow is increased by the measured leakage losses and
documented.
7. Depending on the pressurized system, the necessary operating parameters are checked
and adjusted.
Result
The test is successfully completed if the pressure inside the enclosure does not fall below the
determined minimum pressure over the complete purge time.
The test result is documented in a 3.1 certificate – or in the case that the customer has ordered
the acceptance test, in a 3.2 certificate.
See also
Leakage loss measurement at motors, type of protection "device protection provided by
pressurized enclosure "p"" (Page 61)
3.1.28 Leakage test for water-cooled motors
The water cooling is checked for leaks during production, and is confirmed with a 3.1 certificate.
For motors intended for marine applications, this test represents a hold point with the accepting
organization being present. In this case, a 3.2 certificate is issued.
Tests
3.1 Routine test
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3.2 Additional tests
In the following you will find descriptions of tests that you can additionally order for an induction
motor.
3.2.1 Mechanical tests
3.2.1.1 Overspeed test
Fundamentals
● API 5th edition 6.3.5.6, 4.1.5
● An overspeed test is not required according to IEC 60034-1. However, the overspeed test
is performed when there is an agreement to do so. With the exception of pole-changing
motors, IEC 60034-1 specifies 120 % of the highest safe operating speed of three-phase
induction motors with squirrel cage rotor as speed to be used for the overspeed test.
The overspeed test is used to verify the mechanical strength of the rotor. The bearing housing
and shaft vibrations are evaluated using this test. Increased vibration values can indicate
possible permanent deformation of the rotor after the overspeed test.
At the same time, due to the operation at increased speed by the centrifugal force, a setting
for all rotor parts such as winding, sheets, mounting parts, etc. can be achieved.
The motors are designed for rigid mounting according to EN 60034-14. Some designs require
that the motor is mounted on rubber elements. Within the scope of customer acceptance tests,
the centrifugal speed is determined, based on the rated speed.
Note
For safety reasons, for some special motor versions, the overspeed test can be monitored via
a video camera from a separate room.
Test procedure
1. The motor is rigidly mounted or mounted on rubber elements.
2. The motor is accelerated to its rated speed.
The vibration values are recorded. For sleeve bearing motors, if the appropriate equipment
is available, in addition to bearing housing vibration, also the shaft vibration is monitored.
3. The motor is accelerated to its centrifugal speed.
The overspeed field test is done under no load conditions and takes 2 min.
4. The motor is again accelerated to its rated speed.
Tests
3.2 Additional tests
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5. According to IEC: The vibration values are measured.
6. According to API: The residual unbalance of the rotor (1x component) is vectorially
calculated before and after the overspeed test. The change to this component must not
exceed 10% of the specified vibration limit values.
To determine the 1x vector change, the mean values are calculated from 1x amplitude and
the phase value.
Result
The overspeed test has been successfully completed if no inadmissible increase in the
vibration values is measured. If the values or the vector changes to these values exceed the
vibration limits, the customer must agree the further procedure with the manufacturer.
The overspeed and the duration of the overspeed test is noted in the test certificate. The test
is confirmed in a 3.1 certificate – or in the case that the customer has ordered the acceptance
test, in a 3.2 certificate.
3.2.1.2 Component Balance
Fundamentals
API 4th edition: 2.4.6.3.1a
As a result of the optimized rotor design, two-pole motors operating above the critical speed,
balancing at speeds less than the rated speed in two planes is permissible ("rigid balancing").
"Rigid balancing" is therefore carried out instead of what is laid down in API, which specifies
balancing in three planes at the rated speed.
The components for the motors are already balanced when purchased. A balancing report for
these components is not available.
3.2.1.3 Residual Unbalance Verification Test
Fundamentals
● API 4th edition: 2.4.6.3.6 / 6.2.5.1a
● API 5th edition: 4.4.6.3.4
The precision of the balancing machine is checked with reference to a specific rotor. The test
is performed after the normal balancing of the rotor to the corresponding balance quality
(G = 0.63).
On the balanced rotors, a specific unbalance is created using test weights. The precision of
the balancing machine is evaluated based on the measurement results of the rotor that has
been consciously unbalanced in a specific way.
Test equipment
Balancing machine according to DIN ISO 1940-1
Tests
3.2 Additional tests
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Test procedure
1. The unbalancing weight is consecutively attached to the drive end and non-drive end at 0°,
60°, 120°, 180°, 240°, 300° and 0°. As a consequence, a total of seven balancing runs are
made for each end.
2. A balancing run is made for each position of the unbalancing weight.
For each position / angular degree of the unbalancing weight, the amplitude and phase
angle of the unbalance are output and the resulting unbalance calculated. The resulting
unbalance is compared with the maximum permissible residual unbalance.
Result
If the resulting unbalance is less than or equal to the maximum permissible residual unbalance,
then the test has been successfully completed.
The successful test is confirmed in a 3.1 certificate – or in the case that the customer has
ordered the acceptance test, in a 3.2 certificate.
See also
Vibration severity measurement according to API 541 (Page 39)
3.2.1.4 Final Assembly Running Clearances / Final rotating assembly clearance data storage
Fundamentals
● API 4th edition: 4.2.1.1e
● API 5th edition: 6.2.1.1e
The test ensures that for safe operation there is sufficient clearance between the rotating
components and the stationary, non-rotating components. The test is performed during
assembly, and comprises several parts:
● Air gap
● Distance between shaft fans and air guidance panels (if shaft fans are specified)
● For sleeve bearings: geometrical axial play
● For sleeve bearings, and if specified: Bearing clearance
The test is always performed internally without the customer being present; it is not
documented unless specified otherwise.
3.2.1.5 Inspection for Cleanliness
Fundamentals
● API 4th edition: 4.2.3.2 / 4.2.3.3
● API 5th edition: 6.2.3.3
The cleanliness of the oil inlets and outlets at the sleeve bearings is checked. This avoids that
dirt results in sleeve bearing damage.
Tests
3.2 Additional tests
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Test procedure
1. The cleanliness inspection is carried out immediately before installation.
2. Two to six locations on the oil connection pipes and instrumentation selected by the
inspector are checked for a visual and tangible presence of foreign bodies such as lime,
rust, metallic shavings and sand etc.
Result
The test has been successfully completed if no dirt or pollution has been identified. When the
customer witnesses the test, a 3.2 certificate is generated.
3.2.1.6 Bearing Dimensional & Alignment Checks Before Tests
Fundamentals
● API 4th edition: 4.3.2.1j
● API 5th edition: 6.3.2.1k
The visual inspection of the sleeve bearings and/or the measurement of the geometry proves
the functionality before the electrical tests.
Test equipment
Depending on the specific factory, different test equipment is used, for example the following:
● Cordameter
● 3D measuring machine
● Measuring strips for gap measurement
● Camera
● ...
Tests
3.2 Additional tests
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Test procedure
1. The average bearing clearance between the shaft and bearing shell is determined.
– The diameter of the shaft bearings is measured when the bearings are being
manufactured.
– The bore diameters of the bearing shells are measured during assembly. The
measurement is carried out without customers present.
– The average bearing clearance is calculated as half the difference between the bearing
shell bore diameter and the shaft bearing position diameter. All values are documented
internally; the average calculated bearing clearance is recorded in the test report.
2. The gap between the bearing shell and bearing housing is measured.
Special measuring strips are used to determine the clearance. The selection of the
measuring strips depends on the particular gap.
– The measuring strips are placed on top of the upper bearing shell on both of the inclined
surfaces.
– The upper bearing housing is mounted. During this process, the measuring strips are
crushed between the upper shell and upper bearing housing.
– After removing the upper housing, the crushed measuring strips are compared to the
relevant scale. The suitable strip specifies the existing gap dimension.
Figure 3-17 Example of measuring strips
3. The gap dimensions of the drive-end and non-drive-end bearings are documented
internally. The measured values and photographs are included in the test report.
Result
The test result is documented in a 3.1 certificate – or in the case that the customer has ordered
the acceptance test, in a 3.2 certificate.
Tests
3.2 Additional tests
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3.2.1.7 Bearing Dimensional & Alignment Checks After Tests
Fundamentals
● API 4th edition: 4.3.2.1k
● API 5th edition: 6.3.2.1l
Measuring the sleeve bearing geometry verifies the functionality after the electrical tests.
Test procedure
Once they have cooled down, the sleeve bearings are inspected after the electrical tests.
1. Half the difference between the diameter of the bearing shell bore and the diameter of the
shaft bearing journal is used to determine the average bearing clearance. The diameters
of the bearing journals on the shaft are taken from the previous measurement.
2. The bore diameters of the bearing shells are measured. The measurement is carried out
without customers present.
3. The average bearing clearance is calculated.
Result
All values are documented internally; the average calculated bearing clearance is recorded in
the test report. The test result is documented in a 3.1 certificate.
See also
Bearing Inspection after Tests (Page 60)
3.2.1.8 Vibration Recording
Fundamentals
● API 4th edition: 4.3.3.12
● API 5th edition: -
While the machine is operating at the maximum operating speed and the bearing temperature
is stable (steady state temperature), the vibration amplitudes are evaluated at frequencies
other than the rotational frequency. This range lies between 25 % of the rotational frequency
and four times the line frequency. You can find the limit values in the API 4th edition here:
● Figure 3-5 Limit values for the vibration velocity of the bearing housing (Page 41)
● Figure 3-6 Limit values for shaft vibration (Page 42)
Tests
3.2 Additional tests
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Test procedure
1. The machine is rigidly mounted corresponding to the "Soft Foot test".
2. A bearing temperature rise run is performed.
3. The machine is operated under no load at the rated frequency and rated voltage. A
frequency spectrum in the range from 25% of the rotational frequency to four times the line
frequency is recorded.
Figure 3-18 Example: Frequency spectrum of a two pole 50 Hz machine
Result
If specified, the customer is provided with an electronic data record of the vibration analysis.
See also
Bearing temperature rise (Page 59)
Vibration severity measurement according to API 541 (Page 39)
3.2.1.9 Vibration analysis
Fundamentals
IEC / EN 60034-14
A vibration analysis shows the vibration behavior of the machine over the complete speed
control range.
From the vibration values recorded, for a two pole motor, a beat frequency can be identified,
for example. The resonant frequency can also be determined from the acceleration and coast
down test, as well as the balance state of the installed rotor.
A frequency spectrum is created, which represents vibration in the range from 0 up to 1000 Hz.
Tests
3.2 Additional tests
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Test equipment
Vibration analyzing systems, e.g. ADRE 408 DSPi / Sxp or comparable
Calculations
For machines, which manifest a beat frequency response, vibration variable xrms is calculated
using the following equation:
; ;;HIIPD[PLQ
Test procedure
All of the measured values are continually recorded. For the vibration analysis when operated
from a converter, the operating point is selected, which is specified on the rating plate as
operating point.
1. Run-up: Depending on the actual version, the motor is accelerated using a motor-generator
set up to range between 1.05 and 1.2x rated speed with constant magnetization.
2. Vibration measurement in no-load operation at rated voltage and rated frequency for
15 minutes. The above mentioned formula is applied if a beat frequency response is
identified.
Measurement is shown as trend plot, specifying the overall vibration value; 1X and 2X
components are shown with respect to time. In addition, an FFT spectrum is generated in
the range from 0 to 1000 Hz from the measured data.
3. Coast down in a no-voltage state starting from 1.05x to 1.2x rated speed.
Measurements 1 and 3 are shown as overall vibration value, 1X and 2X components are
shown with respect to the motor speed ("BODE plot").
Result
The measured values are compared with the target values, and specified in the test certificate.
As documentation of the test result, a 3.1 certificate is issued, or for acceptance tests witnessed
by the customer, a 3.2 certificate is issued.
3.2.1.10 Running/Vibration Tests with Coupling Half
Fundamentals
● API 4th edition: 2.4.6.3.3 / 4.3.1.6.2
● API 5th edition: 4.4.9.4 / 6.3.1.5
Tests
3.2 Additional tests
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The vibration response of the machine with balanced customer coupling is determined.
Note
Coupling
The customer must provide the coupling or an equivalent coupling on time, otherwise the test
cannot be conducted.
The customer is responsible for the coupling quality.
Test procedure
1. The machine is rigidly mounted corresponding to the "Soft Foot test".
2. The axial fixing is mounted for machines with sleeve bearing. This is required because the
rotor is no longer maintained at the axial magnetic center following the voltage reduction.
3. A bearing temperature-rise run is performed until a constant bearing temperature is
maintained. The motor is then operated for a further hour at a constant temperature.
4. Vibration measurement at no-load and rated frequency and 25% of the rated voltage.
– The 1x filtered bearing housing and shaft vibrations are measured.
– For the mean value generation, five values of the 1x amplitude and the phase value for
the measuring report are recorded.
5. The customer's coupling is mounted after the motor comes to a standstill.
6. A bearing temperature-rise run is performed until a constant bearing temperature is
maintained. The motor is then operated for a further hour at a constant temperature.
7. The vibration measurement is repeated at 25 % of the rated voltage.
– The 1x filtered bearing housing and shaft vibrations are measured.
– For the mean value generation, five values of the 1x amplitude and the phase value for
the measuring report are recorded.
– The vectorial absolute value change of the vibration between the tests is documented
in the measuring report with and without coupling.
8. The vibration measurement is repeated in no-load operation at the rated frequency and at
the rated voltage. The vibrations are recorded filtered and unfiltered as complete set of
measured data with all sensors.
In addition to the overall vibration, the amplitude is documented with the associated phase
angle for 1x and 2x component in the measuring report.
The vibration values with and without customer coupling are documented.
Result
If the values or the vector changes to these values exceed the vibration limits, the customer
must agree the further procedure with the manufacturer.
The test is documented in a 3.1 certificate – or in the case that the customer has ordered the
acceptance test, in a 3.2 certificate.
Tests
3.2 Additional tests
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See also
"Soft Foot test" according to API 541 (Page 37)
3.2.1.11 Unbalance Response Test
Fundamentals
● API 4th edition: 4.3.5.3
● API 5th edition: 6.3.5.3
API 541 specifies the unbalance response test and defines the limit values for shaft vibration
levels.
The unbalance response test verifies that all of the critical speeds have a minimum safety
margin of 15 % from the rated speed or from the permissible speed control range and also to
determine that the rotor does not manifest any excessively high vibration levels when it passes
through the first critical speed.
The unbalance response test is also used to localize the first critical speed. The position of the
first critical speed is also influenced by the weight of the coupling. This is the reason that this
test is performed with the customers coupling if this is available.
Only motors equipped with sleeve bearings can be tested, where the balancing planes are
accessible. This is the reason that the test is not possible for motors with flameproof enclosure.
Test procedure
1. The machine is rigidly mounted corresponding to the "Soft Foot test".
2. Known balance weights are attached in phase with one another at the DE and NDE system
balancing plates.
3. In no-load operation, the motor is brought up to 120 % of the rated speed and then runs
without any power.
4. After each coast down, the balancing weights are shifted through 90°. The measurement
is repeated for 90°, 180° and 270°.
Tests
3.2 Additional tests
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Result
The test has been successfully completed if the limit values for the range ± 15 % are maintained
– and the rated speed and limit values are maintained for the remaining range.
Figure 3-19 Example: Measurement result of dynamic unbalance test
The successful test is confirmed in a 3.1 certificate – or in the case that the customer has
ordered the acceptance test, in a 3.2 certificate.
See also
Vibration severity measurement according to API 541 (Page 39)
3.2.1.12 Bearing Housing Natural Frequency Tests
Fundamentals
● API 4th edition: 4.3.5.4
● API 5th edition: 6.3.5.4.1
Motor components, such as the bearing housing, rotor, motor enclosure etc., together form a
system that is capable of vibration at various natural frequencies, depending on the component
being considered, such as the bearing housing, motor enclosure etc. The natural frequencies
of the components decoupled from one another (i.e. separately considered) are different than
those for the assembled motor. As a consequence, the resonant frequencies of these
components are determined at a completely assembled machine; in this case only the natural
frequency of the bearing housing.
According to API 541 4.3.1.4, a motor without a terminal box is considered a completely
assembled machine.
The most important excitation sources for the bearing housing vibration of a motor include the
rotor rotational frequency, and especially for two-pole machines, twice the line frequency. If
one of these exciting frequencies coincides with the resonant frequency of the bearing housing
in the mounted state, then excessive vibration levels are manifested at the bearing housing.
This test indicates the resonant frequency of the motor bearing housing.
Tests
3.2 Additional tests
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Test procedure
1. The machine is rigidly mounted corresponding to the "Soft Foot test".
2. Motors with sleeve bearings: The rotor must rotate slowly in order to bring it into a defined
state. To do this, the motor is operated in the speed range from 200 up to 300 rpm.
3. Motors with roller bearings: The rotor does not have to rotate.
4. Using a hammer, bearing housing vibration is excited in the directions to be measured
(horizontal, vertical and axial).
The vibration is recorded, analyzed and the natural frequency determined.
Figure 3-20 Positioning the pickups at DE
Figure 3-21 Positioning the pickups at NDE
The measured values are displayed in a plot for the frequency range from 0 to 400% of the
line frequency.
If bearing housing resonance is determined, which coincides with the rotor rotational frequency
or twice the line frequency, then the appropriate countermeasures are defined together with
the customer.
Result
The successful test is confirmed in a 3.1 certificate – or in the case that the customer has
ordered the acceptance test, in a 3.2 certificate.
See also
"Soft Foot test" according to API 541 (Page 37)
Runout measurement with acceptance (Page 52)
Tests
3.2 Additional tests
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3.2.1.13 Visual inspection
Fundamentals
The visual inspection verifies that the order specifications are complied with.
Test procedure
The visual inspection together with the customer – or with the company accepting the
equipment – is carried out using the motor that has been completely painted and the
appropriate labels attached.
The visual inspection includes the following steps:
● The outside of the motor is inspected and assessed.
● The instrumentation is explained based on the electrical/mechanical documentation and
dimension drawing.
● The customer or the company accepting the motor on the customer's behalf can check the
outer dimensions.
● Digital photographs are made that clearly document the situation.
Note
● The terminal box and auxiliary terminal boxes are not opened.
● Test reports are not handed over and discussed.
● It is possible that the motor is already mounted on a shipping pallet.
● A rotor holding brace can already be attached, i.e. the shaft face cannot be seen.
Result
A paint thickness measuring report is generated. The test result is documented in a 3.2
certificate.
3.2.1.14 Paint thickness measurement
Fundamentals
The measurement is performed according to DIN EN ISO 2064. The paint film thickness
measurement serves to verify the agreed film thickness, and is performed without the customer
being present. When ordered, every film thickness is individually measured and documented.
Test equipment
A dry paint film thickness measuring instrument that is suitable for ferritic and non-ferritic
surfaces. The measuring instrument works according to the following methods:
● Magnetic process according to DIN EN ISO 2178
● Eddy current process according to DIN EN ISO 2360
Tests
3.2 Additional tests
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Test procedure
At defined measuring points on the machine, the thickness of the applied paint film is measured
five times. The average value of the paint film thickness is calculated.
The measurement locations specified in the following are not available or not possible at all
motors.
1. Housing (top); for fin cooling: Power cable duct
2. Housing (at the side)
3. Foot or flange
4. Terminal box cover
5. Fan cover or air intake cowl
6. Bearing shield
7. Anti-friction bearing cover or sleeve bearing housing
8. Upper part of the enclosure underside
9. Upper part of the enclosure top
10.Upper part of the enclosure front face on the drive end, for IM V1 on the non-drive end
11.Upper part of the enclosure side
12.Protective cover (top)
13.The paint film thickness measurement protocol shows the measuring points and the
measured layer thicknesses are entered with their average values.
Result
The test result is documented in a 3.1 certificate.
3.2.1.15 Heat exchanger performance verification test TEWAC
Basis for testing
● API 6.3.3.5
The test establishes whether the TEWAC heat exchanger has been adequately designed to
cool the air in the motor. Inadequate cooling impairs motor performance. TEWAC stands for
"Totally Enclosed Water to Air Cooled".
The test can only be carried out under test facility/test field conditions regarding the cooling
water supply.
Test procedure
1. The cooling water supply is connected.
2. The cooling water is set to nominal flow, temperature and pressure on the water supply,
where possible.
3. A temperature rise test under load is performed.
Tests
3.2 Additional tests
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Result
The test is passed if no leaks or pressure losses occur for at least 30 minutes and the specified
heat dissipation is achieved. The test result is documented in a 3.1 certificate – or in the case
that the customer has ordered the acceptance test, in a 3.2 certificate.
See also
Temperature rise test under load (Page 79)
3.2.1.16 Hydrostatic test
The compressive strength of the air-to-water heat exchanger is confirmed by a 3.1 certificate
from the manufacturer. The air-to-water heat exchanger can also be tested underwater using
air as a test medium, and documented accordingly.
3.2.2 Electrical tests
3.2.2.1 Temperature rise test under load
Fundamentals
● IEC 60034-1
● IEC 60034-29
● IEEE 112 (5.8.3a, c)
The temperature rise test under load is carried out to determine the temperature rise for
operation at rated load or another load.
For machines in compliance with API 541, the temperature rise test under load must be for at
least four hours.
Without special agreements, and as long as the rated power of the machine to be tested lies
within the power range of the load equipment (dynamometer) the temperature rise test is
carried out at the rated load of the machine to be tested.
If the rated power of the machine to be tested exceeds the maximum power of the load
equipment (dynamometer), then temperature rises are determined indirectly using equivalent
load or interpolation techniques.
● IEC 60034-29
– Equivalent load: Test with modified supply frequency
– Superposition technique
● IEEE 112:
– Forward stall equivalent method
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+]Q00aaa*0a
①Test specimen
②Load machine (dynamometer)
③Measuring point for speed and torque
Figure 3-22 Schematic diagram: Test setup at frequency = 50 Hz
ำ+]Q00aaa*a0aaa*0a
①Test specimen
②Load machine (dynamometer)
③Measuring point for speed and torque
④Rotating motor-generator set
Figure 3-23 Schematic diagram: Test setup at frequency ≠ 50 Hz
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Test procedure
1. Temperature sensors are integrated at defined measurement locations in the motor. During
the test, the actual temperature of the sensors is continually recorded. The motor is only
shutdown once the steady-state temperature has been reached.
Channel 1
Channel 2
Channel 3
Channel 4
Channel 5
Channel 6
Channel 14
Channel 16
Channel 17
Channel 18
t (h)
0
10
20
30
40
50
60
70
80
90
100
14:30 15:00 15:30 16:00 16:30 17:00 17:30 18:00 18:30 19:00 19:30 20:00
T (°C)
Channel Measurement location
① ... ⑥Slot
⑭Inlet air external
⑯Outlet air external
⑰Ambient
⑱Drive-end bearing
Figure 3-24 Example of a plot for a temperature rise test under load
2. The resistance when warm is measured.
3. The cooling-down curve is recorded by measuring the stator winding resistance. The
average motor temperature rise at the instant of shutdown is derived from this curve.
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WV
55
Figure 3-25 Example of a cooling-down curve, measurement for example after 50 s
ϑ2 - ϑa = (R2 - R1) · (ϑ1 + 235) - 235 - ϑa
ϑ1 temperature of cold winding
ϑ2 temperature of warm winding
ϑa coolant temperature
R1resistance of cold winding
R2resistance of warm winding
Result
The temperature increase is obtained from the ratio between the resistance of the stator
winding when warm and when cold, and is documented together with the measuring data in
the acceptance test certificate. The temperatures measured during the course of the test are
shown in the temperature plot.
The calculated temperature rise must lie within the limits of the defined temperature class, e.g.
corresponding to the following table.
Table 3-4 temperature class / temperature rise of stator and rotor windings
Temperature Class Temperature rise
B 80 K
F 105 K
As documentation of the test result, a 3.1 certificate is issued, or for acceptance tests witnessed
by the customer, a 3.2 certificate is issued.
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See also
Testing of accessories, integrated and mounted components (Page 45)
3.2.2.2 Testing the temperature limits of components in explosion-protected motors
Fundamentals
● IEC / EN 60079-0; -1; -2; -7
● PTB test regulations, Volume 3: "Test and certification in accordance with Directive 2014/34/
EU for explosion-protected drives".
The temperature limits of the various materials and/or components used in the machine are
tested corresponding to the thermal properties. If necessary, the test is carried out
corresponding to the specified temperature classes. It is not permissible that the limit values
are exceeded.
Test equipment
● Thermo elements or resistor sensors
● Handheld thermometer
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Test procedure
1. A temperature rise test under load (Page 79) is performed.
2. The temperature values are documented at the defined measurement locations according
to IEC / EN 60079-0 and the appropriate test rules & regulations of the PTB.
3. All measured values are interpolated up to the maximum ambient temperature and rated
values - and compared with the limit values of IEC / EN 60079-0; it is not permissible that
the limit values are exceeded.
Measurement location according to the
temperature class
Maximum surface temperature
T1 450 °C
T2 300 °C
T3 200 °C
T4 135 °C
T5 100 °C
T6 85 °C
Measurement location Maximum surface temperature
Normal, undisturbed oper‐
ation
Overload/fault
Cable entry ②70 °C
>70 °C ①
80 °C
>80 °C ①
Conductor branch ②80 °C
>80 °C ①
95 °C
>95 °C ①
Seals, non-metallic parts of the enclosure Corresponding to the certification documentation
① With notification label according to IEC / EN 60079-0 on heat resistant cable or cable entry with
temperature data
② The limit values listed in the table are appropriately reduced when using cables or cable entries
with lower temperature resistance.
Result
The test result is documented in a 3.1 certificate – or in the case that the customer witnessed
the acceptance test, in a 3.2 certificate.
3.2.2.3 Short-circuit temperature rise test for motors with type of protection Ex e
Fundamentals
● IEC / EN 60079-7
● PTB test regulations, Volume 3: "Test and certification in accordance with Directive 2014/34/
EU for explosion-protected drives".
Ex e machines are suitable for use in Zone 1, and are therefore assigned to Category 2.
Category 2 states that also for common operating faults, protection is to be provided (locked
rotor).
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For explosion protection, as critical fault situation, it is assumed that the motor has reached
its final operating temperature after many hours of operation at rated load under unfavorable
cooling conditions, and that the rotor is locked as a result of a fault. The results from continuous
operation and the short-circuit temperature rise are evaluated and the tE time (locked rotor
time) determined.
If at all possible, the short-circuit temperature rise test is carried out at the rated voltage. The
duration of the test is defined based on the machine size and type of construction.
Note
The test is carried out within the scope of a type test, and cannot be ordered.
Test equipment
● Supply equipment: Transformer with supply at the rated frequency
● Locking equipment for rotors, e.g. a starting torque test stand
● Temperature measuring equipment
● Fast plotter
Test procedure
The short-circuit temperature rise test is carried out twice as minimum: in various rotor positions
or in both directions of rotation.
1. According to the directives of the nominated body, e.g. the Physikalisch Technischen
Bundesanstalt (PTB), the rotor is equipped with thermo elements. During the test, the
temperature values are recorded using a temperature plotter.
2. The winding resistance when cold is measured.
3. The motor is switched on. The electrical values are documented.
– 5 seconds after switch on
– Shortly before switching off
4. After the machine has been switched off, the winding resistance when warm is measured.
This determines the average winding temperature rise reached during the short-circuit
temperature rise test.
5. Together with the results of other temperature rise tests performed under load, the tE time
(locked rotor time) is determined.
All of the measurement results form the basis for certification issued by the nominated body.
Result
The measurement is internally documented.
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3.2.2.4 "tan δ" loss factor measurement on single coils
Fundamentals
The dielectric losses in the main insulation (slot part of the coil with respect to ground) are
determined at the individual coils.
The coils are manufactured in the same production processes from the same material batches
as the winding of the machine itself. Impregnation is carried out in slot models, whose slot
dimensions correspond to the laminated core slots and in the same impregnation process as
the winding itself.
,,-8,:,%ˡ˳
Figure 3-26 Definition of the loss factor tan δ
The loss factor is defined as the ratio between the active and reactive current:
tan δ = IW / IB
When carry out measurements at individual coils, the influence of edge fields and the ohmic
electric field strength distribution (potential grading) can be essentially eliminated using shield
electrodes. This allows the state of the slot insulation alone to be assessed.
Test equipment
A classic Schering measuring bridge or another electronic measuring system is used to
measure the loss factor. The measuring circuit for an electronic measuring system and the
test object with shield electrodes (coil side or bar) is shown in the following sketch. More
information is available in IEC 60034-27-3.
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7HVWREMHFW&;6HQVRU6HQVRU5HIHUHQFHEUDQFK0HDVXUHPHQWEUDQFK/DSWRS*URXQGHGVKLHOGULQJV&;)2)2&.&0&5
Figure 3-27 Sketch showing the principle: Loss factor measurement at single coils
Test procedure
1. For coils, the two coil sides (upper or lower coil side) are separately measured and
evaluated.
A 50 Hz AC voltage is used for the test with an increment of ΔU = 0.2 UN – starting with
0.2 UN to 1.2 UN.
2. Alternatively, for electronic measuring systems, a continuous measurement is possible with
the appropriate evaluation in 0.2 UN steps.
3. The characteristic values, defined in the table, are generated from the measured loss factor.
Characteristic values Formula Limit
Initial value at 0.2 UNtan δ0.2 20 · 10-3
Maximum rise per 0.2 UNΔtan δmax / 0.2 UN5 · 10-3
Average initial increase between
0.6 UN and 0.2 UN
tan δ0.6 – tan δ0.2 5 · 10-3
Result
The characteristic values must, as a minimum, comply with the requirements laid down in
IEC 60034-27-3 or the associated specification.
3.2.2.5 Loss factor and capacitance measurement on the complete winding or machine
Fundamentals
The test corresponds to the "Power Factor Tip-Up Test" according to API. At the complete
winding or machine, the dielectric losses in the main insulation (winding with respect to ground)
of the high voltage windings are determined.
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,,-8,:,%ˡ˳
Figure 3-28 Definition of the loss factor tan δ
The loss factor is defined as the ratio between the active and reactive current:
tan δ = IW / IB
The loss factor measurement is a summarizing measurement; this means that all dielectric
losses are measured, including the losses of the edge fields and the electric field strength
distribution (overhang corona shielding). The influence of edge fields and electric field strength
distribution (overhang corona shielding) decreases with increasing laminated core length.
The overall losses are made up as follows:
● Transmission losses in the dielectric, essentially independent of the voltage
● Cable losses at the surface (electric field strength distribution (overhang corona shielding),
pollution/dirt). The electric field strength distribution (overhang corona shielding) losses
increase with increasing voltage.
● Losses caused by partial discharge in voids or gaps. These losses depend on the voltage.
These losses can indicate the state of the overall insulation.
Test equipment
The measuring methods and requirements relating to winding insulation of rotating electrical
machinery are described in Standards DIN EN 50209, IEC 60894 and IEC 60034-27-3
The classic Schering measuring bridge or electronic measuring systems is used. Alternatively,
measuring circuits to measure grounded test objects (machine in the test bay) are used. A
detailed description can be found in IEC 60034-27-3.
The following block diagram shows the loss factor measurement using a Schering bridge and
grounded machine.
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①Test voltage
②Standard capacitor
③Measuring bridge
Figure 3-29 Loss factor measurement of complete windings or machines
Measuring procedure
● Accessible and open neutral point: The voltage-dependent capacitance and loss factor
values are measured from 0.2 UN to 1.2 UN in 0.2 UN steps.
– At the complete winding U+V+W
– Optionally, at the individual phases U, V, W
● The machine enclosure and the winding phases that are not being measured are grounded.
● With the neutral point closed, the complete winding is measured with respect to the housing
(ground).
Result
In addition to the dielectric itself, the loss factor also depends on the machine size and specific
design features such as how the overhang corona shielding is implemented. Limit values for
loss factor parameters of windings are not specified in the standards. If loss factor
measurements at the winding are requested, the results are purely of an informative nature.
For instance, they are used as reference when making measurements to diagnose the state
of windings based on their dielectric properties.
Note
Limit values mean that individual agreements have to be made with customers on a case-for-
case basis.
The loss factor characteristic over a voltage range from 0.2 up to 1.2 UN and the parameters
determined from it, defined in the following, are specified.
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3.2.2.6 Power Factor Tip-Up Test
Fundamentals
● API 4th edition: 4.3.4.3
● API 5th edition: 6.3.4.3
The loss factor measurement corresponds to test "Loss factor and capacitance measurement
on the complete winding or machine (Page 87)".
The successful completion of the test is confirmed in a 3.1 certificate.
3.2.2.7 Stator Core Test
Fundamentals
● API 4th edition: 4.3.4.1
● API 5th edition: 6.3.4.1
During the "ring core magnetization" test, closed, ring-shaped material samples, yokes or
unwound or wound stators of electrical machines, in which a magnetic field is generated in a
tangential direction, are examined. Hereinafter, these parts are referred to as "yoke".
Defects of the laminated core insulation can cause eddy currents that can result in an excessive
increase of the sheet temperature (hotspots). Hot spots can cause coil faults.
During the test, the characteristic magnetization characteristic B = f(H) or the specific no-load
losses vFE = f(B) are optionally recorded. To a certain extent, the insulation of the laminations
can be checked against each other by magnetizing the laminated stator core. Faults are
detected that cause an inadmissible local temperature rise of the stator core.
./$NO8ZO8IZ%-+-
f Excitation frequency w1Number of excitation windings
U1Excitation voltage w2Number of measurement windings
U2Measuring voltage PwActive power
I1Excitation current BJMaximum yoke induction
①Wattmeter 7KB 4306 Values I, U2, Pw, cos φ are displayed on the Wattmeter.
Figure 3-30 Example of a test setup
The test is executed by applying a defined induction in the laminated core by attaching coils
similar to a transformer winding.
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Figure 3-31 Stator
Test procedure
1. The cables for the specified excitation winding with number of turns w1 are placed along
the shortest path around the laminated core. The cables can also wind around the housing.
The windings are distributed as evenly as possible around the circumference. The
measurement winding with number of turns w2 is optionally placed in a groove around the
yoke of the laminated stator core and between the laminated core and pressure plate. The
winding is placed on the back of the laminated core and the remainder of the cable is twisted.
2. The voltage is increased at the test coils until the ring core is almost magnetized to its
nominal induction level. As a consequence, the laminated stator core temperature
increases.
3. During the 30-minute measuring period, the temperature rise is continuously monitored
using a heat imaging camera.
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4. Thermal images of the hot spots are recorded at various points in time to document how
the temperature changes.
Figure 3-32 Example of a heat image
5. A magnetization characteristic to determine the specific core losses with a continuously
increasing magnetization of the ring core is optionally recorded.
Result
In comparison with other machines, differences can be identified and can be analyzed if
necessary. The successful test is confirmed in a 3.1 certificate – or in the case that the customer
has ordered the acceptance test, in a 3.2 certificate.
3.2.2.8 Special Surge Test of Coils
Fundamentals
● API 4th edition: 4.3.4.2.1
● API 5th edition: 6.3.4.2.1
● IEC 60034-15
The pulse withstand capability of the inter-turn/layer and main insulation of the winding is
verified at two separately manufactured individual coils. The coils are manufactured in the
same production processes from the same material batches as the winding of the machine
itself. Impregnation is carried out in slot modules, whose slot dimensions correspond to the
laminated core slots and in the same impregnation process as the winding itself.
The surge voltage test is carried out in two different test circuits:
● Test of the main insulation (= slot area and electric field strength distribution (overhang
corona shielding))
● Test of the inter-turn and layer insulation (= insulation between the conductors)
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Figure 3-33 Surge voltage test block diagram
The requirements and criteria according to IEC 60034-15 are applied as standard.
Requirements going beyond this, e.g. as a result of customer specifications, must be agreed
on a case-for-case basis.
Table 3-5 Test criteria according to IEC 60034-15
Test Amplitude Rise time Time to half value Number of pul‐
ses
Main insulation Ûmain = 4 · UN + 5 kV 1.2 µs ±30 % 50 µs ±20 % 5
Inter-turn/layer insu‐
lation
Ûcoil = 0.65 · Ûmain 0.2 ± 0.1 µs up to UP = 35 kV
0.2 +0.3/-0.1 µs from UP > 35 kV
- 5
The values depend on the coil and test circuit impedance, and typically lie between 5 and 10 µs.
Table 3-6 Test criteria according to API 541 5th Edition
Test Amplitude/
Test voltage
Rise time Time to half value Number of pul‐
ses
Partial discharge
measurement only
for coils with over‐
hang corona shield‐
ing
√3 · UNn.a. n.a. n.a.
Main insulation 5.0 pu 1.2 µs 50 µs 3
Winding insulation 2.0 pu / 3.5 pu 0.1 ... 0.2 µs * n.a. At least 1 pulse
per minute
Breakdown test/
puncture test of the
winding insulation
The voltage is increased
in 5 kV steps
0.1 ... 0.2 µs n.a. 1
* This value is dependent on the coil and can deviate from the values listed here
According to IEEE 522 6.2, the pu (per unit) is calculated as follows:
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Test procedure
1. The voltage is increased, starting from approx. 50 % of the test voltage amplitude to be
applied up to the specified impulse withstand voltage in steps of approx. 3 kV. Three voltage
surges (pulses) are applied per voltage stage.
2. For the impulse withstand voltage, as a minimum, the voltage impulses are applied
corresponding to the relevant table.
3. For tests according to the API 5th Edition - or optionally according to IEC 60034-15 - after
the main insulation test, the test voltage is increased step-by-step until either the strength
of the main insulation or the clearance in air breaks down ("Breakdown Test").
Result
At the specified impulse withstand voltages, it is not permissible that there is any arcing across
the main or inter-turn insulation. Every surge voltage value is documented during the test. The
curve is graphically depicted in order to guarantee that deviations in the curve form, which
could indicate faults, can be detected as the voltage increases.
The successful test is confirmed in a 3.1 certificate – or in the case that the customer has
ordered the acceptance test, in a 3.2 certificate. It contains the test results and the voltage
curve forms as graphical representation.
3.2.2.9 Partial discharge test
Fundamentals
● API 5th edition: 6.3.4.6
● The measurement is in conformance with IEC 60034-27-1
Using the partial discharge measurement, electrical discharges in voids (gas pockets) inside
the insulation or at transitional surfaces, e.g. at insulation surfaces, can be detected. In contrast
to the integrating loss factor measurement, the partial-discharge measurement is differential
in character. This means that it can identify limited local weak points on the insulation.
This test measures the apparent single pulse charges q in a wide-band frequency range as a
function of the amplitude of the applied AC voltage. The most important recorded values
include the partial-discharge inception voltage, the maximum pulse charge at the phase
voltage UN/√3 (operating voltage of the winding with respect to ground) and rated voltage UN.
The phase distribution, frequency and polarity of the discharges can also be measured. This
provides additional information regarding the source and significance of the discharge.
In conjunction with other diagnostic measurements and, where possible, trend monitoring, this
testing technique allows the insulation condition to be evaluated.
Tests
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3DUWLDOGLVFKDUJHPHDVXULQJV\VWHP&DOLEUDWLQJSXOVH&RXSOLQJXQLW&RXSOLQJFDSDFLWRU9ROWDJHVRXUFH:LQGLQJ
Figure 3-34 Measuring circuit for the partial discharge measurement
● Broad-band partial discharge measuring system compliant with IEC 60270
● Controllable voltage source
Measuring procedure
1. The partial discharges are measured for an increasing as well as decreasing test voltage
between 0 and UN, optionally up to 1.2 UN.
2. All partial discharge events are saved with the correct phase, time, amplitude and polarity
and analyzed by software.
3. Essential results:
– Maximum apparent single pulse charges as a function of the voltage (Q(U) curves)
– Partial discharge pattern (in-phase amplitudes and frequencies of the partial discharges)
– Amplitude-specific frequency distribution of the partial discharges
4. Wherever possible, the measurement is recorded for the entire winding U+V+W. Phases
U, V, W are optionally recorded.
If the neutral point is accessible, the values for X, Y, Z and X + Y + Z are recorded.
5. The partial discharge parameters are visualized and documented.
Result
Presently, there are no limit values listed in the standards. Requirements from customer
specifications must be agreed on a case-for-case basis. The results can be subsequently used
as reference to diagnose the winding condition. In order that the measurement results can be
compared, measuring systems and a defined measuring circuit with essentially identical
parameters are required.
The successful completion of the test is confirmed in a 3.1 certificate.
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3.2.2.10 Recording the no-load characteristic and calculating losses separately
Fundamentals
The no-load characteristic is used to determine the iron and friction losses of the motor.
The no-load characteristic is recorded after stabilization of the no-load losses. The no-load
losses are considered to have stabilized as follows:
● When the recorded no-load power of two consecutive measurements taken on a cold
machine at an interval of 30 min changes by a maximum of 3%.
● When the no-load test is carried out immediately after the load test.
Test procedure
Measuring the no-load characteristic
1. The winding resistance of the cold motor is measured.
2. Variables U0, I0, P0 are measured at a constant frequency for eight voltage values in the
range from 110 % up to 30 % UN in a descending order.
3. The no-load characteristic is generated by entering Pk and I0 with respect to U0².
The constant losses Pk are the no-load losses, adjusted by the no-load winding losses (PS0),
with the winding resistance of the cold machine (R) and no-load current (I0).
Pk = P0 - PS0
Ps0 = 1.5 · I0² · R
The constant losses are the sum of the friction and windage losses (Pfw) and the iron losses
(Pfe).
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Separating the losses
1. The friction losses Pfw are determined from the no-load characteristic by extrapolating the
Pk graph to voltage 0 V.
881t,$3N:,$3N:
Figure 3-35 Determining the friction losses from the no-load characteristic
2. Iron losses Pfe = P0 – PS0 – Pfw at the rated operating point are determined from the no-load
characteristic, at the voltage reduced by the ohmic voltage drop in the primary winding Ui.
8 8y,y5yFRV˳,y5yVLQ˳
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Result
The results of the test are confirmed in a 3.1 certificate – or in the case that the customer has
ordered the acceptance test, in a 3.2 certificate.
Tests
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3.2.2.11 Recording the short-circuit characteristic and short-circuit losses
Fundamentals
The short-circuit characteristic is recorded to check the rotor, the rotor winding and the current
symmetry.
Test procedure
1. With the rotor mechanically locked, the motor is fed with a variable voltage at the rated
frequency. The voltage amplitude (short-circuit voltage) is varied until the specified values
for the stator currents are obtained.
2. As standard, three measurement points are recorded at 50 %, 100 % and 160 % rated
current.
The short-circuit voltage is compared with the internal test specifications and the current
symmetry is monitored in the various phases.
Additional statements regarding the starting torque and starting current (inrush current) can
be made based on the results of the short-circuit characteristic.
Result
The measured values are listed in the form of a table in the measurement report. The
successful test is confirmed in a 3.1 certificate – or in the case that the customer has ordered
the acceptance test, in a 3.2 certificate.
See also
Short-circuit test (Page 36)
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3.2.2.12 Plotting the load characteristic
Fundamentals
The load characteristic is required to determine the load-dependent losses. It represents
characteristic data of the machine under various load conditions. Based on the load
characteristic (operating diagram), information can be obtained regarding the operating points
in subsequent operation.
A load characteristic, where conclusive comments can be made, must be recorded with the
motor in the warm state after a temperature rise test under load. If the load characteristic (option
F18/F19) was ordered without temperature rise test (option F04/F05) then it is recorded with
the motor in the cold state.
Test procedure
The test is carried out with the motor in an operationally warm condition if the temperature rise
test under load (option F04/F05) was ordered. If a temperature rise test under load was not
ordered, then the load characteristic is recorded with the motor in the cold condition.
The measurement starts with the highest load point and ends with the lowest.
Variables U, I, P1, R, n, f, T are recorded for each load point.
1. The resistance is measured before recording the first load point. This resistance is used
for all load points.
2. The machine is loaded at six load points in the range from 25 % up to 150 % PN.
– Four load points, evenly distributed in the range between 25 % and 100 % PN are
recorded.
– Two load points are recorded at 110 % and at 125 % PN.
According to the standard, resistance R is measured before the highest load point and after
the lowest load point.
● As resistance for 100 % PN and higher load points, the value that was determined before
the highest load point applies.
● As resistance for load points below 100 % PN, that value should apply, which was
determined before the highest and after the lowest load point at 25 % PN under the
assumption of a linear characteristic between these two points.
Generally, the load test is carried out so fast (<5 min) that the influence of the low temperature
change – that takes place while recording the load characteristic – has very little impact on the
resistance. The low temperature change is as a result of the large thermal time constant of the
motor. This applies to all SIMOTICS HV and SIMOTICS TN motors.
For this reason, in deviation to the standard but favorable to the customer, the measured
resistance from the highest load point can be used for all load points.
Tests
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Result
The load characteristic with data regarding cos φ, I and n is generated from the measured
values. The result is confirmed in a 3.1 certificate – or in the case that the customer has ordered
the acceptance test, in a 3.2 certificate.
QUSP331FRV˳,QFRV˳,$
Figure 3-36 Example of a load characteristic
See also
Calculating the efficiency from the individual losses (Page 103)
Temperature rise test under load (Page 79)
Tests
3.2 Additional tests
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3.2.2.13 Recording the starting torque and current
Fundamentals
Checking the locked-rotor current and the starting torque checks whether the motor starting
behavior complies with what has been specified.
Note
As an alternative to the test procedure described here, the values can also be determined from
the short-circuit characteristic.
Test procedure
1. The motor is coupled with the dynamometer and a torque measuring shaft and is fed with
the rated voltage at 50 / 60 Hz.
2. The dynamometer is controlled at zero speed so that the starting torque generated by the
motor is measured at the torque measuring shaft. The locked-rotor current is also measured
in the stator feeder cable.
The average values from the three measuring points provides the starting torque and the
locked-rotor current at the rated voltage.
3. If the motor cannot be tested at the rated voltage, then the current and torques are
measured at the highest possible voltage and additional lower voltages. The locked-rotor
current and starting torque are then extrapolated up to the rated voltage.
Result
The measured values and the locked-rotor torque and current calculated from these values
are documented in the measurement report. The test has been successfully completed if the
locked-rotor current and starting torque are within the specified tolerances.
The successful test is confirmed in a 3.1 certificate – or in the case that the customer has
ordered the acceptance test, in a 3.2 certificate.
See also
Recording the current and torque characteristics using a dynamometer (Page 102)
Tests
3.2 Additional tests
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Reference Manual 05/2018 101
3.2.2.14 Recording the current and torque characteristics using a dynamometer
Fundamentals
This test should provide a conclusive statement regarding the acceleration performance of a
machine. By comparing the motor characteristic and the expected load torque characteristic
curve, the accelerating torque (excess torque) is determined. The excess torque is defined as
the difference between the motor torque and the load torque of the driven machine. This can
be used to verify correct acceleration of the entire machine unit.
Test procedure
1. The motor is coupled with the dynamometer and a torque measuring shaft and is fed with
the rated voltage at 50 / 60 Hz.
2. The dynamometer is controlled at various speeds between zero and synchronous speed.
The torque generated by the motor and the current in the stator cable are measured at the
various speeds.
The acceleration characteristic is obtained from these measuring points.
If, for system-related reasons, the motor cannot be tested at the rated voltage, then the
acceleration characteristic is recorded at the highest possible voltage, and then subsequently
extrapolated to the rated voltage. The prerequisites in this case is that the starting torque test
is carried out at the same voltage and is extrapolated up to the rated voltage.
The measured variables are documented in the measurement report and extrapolated up to
the rated voltage. Current and torque with respect to the speed are entered in a diagram. The
highest measured value in the torque characteristic corresponds to the breakdown torque, the
lowest measured value, the pull-up torque.
Alternatively: Test procedure according to IEEE 112
The torque-speed characteristic is the relationship between the torque and speed of the motor
in the range from 0 speed up to synchronous speed. Starting torque and motor breakdown
torque are determined from the diagram.
The torque-speed characteristic is determined from the speed change, as the torque available
is proportional to the speed change.
Result
The test has been successfully completed if the breakdown torque and the pull-up torque
remain within the specified tolerance. The successful test is confirmed in a 3.1 certificate – or
in the case that the customer has ordered the acceptance test, in a 3.2 certificate.
See also
Recording the starting torque and current (Page 101)
Tests
3.2 Additional tests
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3.2.2.15 Calculating the efficiency from the individual losses
Fundamentals
It is conducted in compliance with the following standards:
● IEC 60034-2-1: Individual loss method
● IEEE 112: Method B (PLL measured) or method E1 (PLL assumed)
Note
Ordering options
The following options for calculating the efficiency from the individual losses are required, and
must be ordered in addition to F20/F21:
● Temperature-rise test under load (F04/F05)
● Recording the no-load characteristic and determining the iron (core) and no-load losses
(F14/F15)
● Recording the load characteristic (F18/F19)
Note
The following text includes formula symbols and statements from IEC 60034-2-1. The definition
of the symbols can be taken from this standard. As a result of the analogous approach, this
description is also applicable for methods B and E1 from IEEE 112.
Test procedure
1. The winding resistance of the cold motor is measured.
2. A temperature rise test under load is performed. The following variables are recorded at
the end of the temperature-rise test under load:
PN, IN, UN, s, f, θc, θN, RN
Tests
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3. The load characteristic is recorded with the motor in a warm operating condition. The
measurement starts with the highest load point and ends with the lowest. Variables U, I,
P1, R, n, f, T are recorded for each load point.
– The resistance is measured before recording the first load point. This resistance is used
for all load points.
– The machine is loaded at six load points in the range from 25 % up to 150 % PN.
- Four load points, evenly distributed in the range between 25 % and 100 % PN are
recorded.
- Two load points are recorded at 110 % and at 125 % PN.
According to the standard, resistance R is measured at the highest load point and after the
lowest load point.
– As resistance for 100 % PN and higher load points, the value that was determined before
the highest load point applies.
– As resistance for load points below 100 % PN, that value should apply, which was
determined before the highest and after the lowest load point at 25 % PN under the
assumption of a linear characteristic between these two points.
Generally, the load test is quickly performed (<5 min). The low temperature change that
occurs while recording the load characteristic plays a secondary role on the resistance.
The low temperature change results from the high thermal time constant of
SIMOTICS HV and SIMOTICS TN motors.
4. The motor is decoupled from the dynamometer.
5. The no-load characteristic is recorded with the motor in a warm operating condition.
– Variables U0, I0, P0 are measured at a constant frequency for eight voltage values in
descending order in the range from 110 % down to 30 % UN.
– The no-load characteristic is generated by entering Pk and I0 with respect to U0².
Constant losses Pk are described in the following.
6. The efficiency is calculated.
Calculating the efficiency
The efficiency is defined as follows:
η = P2 / P1
The difference P1 - P2 is the total power loss Pt. The power loss PT is made up of the individual
losses:
Pt = Pk + Ps + Pr + PLL
These include constant losses (Pk), load-dependent stator winding losses (Ps), rotor winding
losses (Pr), supplementary losses (PLL).
Constant losses Pk
The constant losses Pk are the no-load losses, adjusted by the no-load winding losses (PS0),
with the winding resistance of the cold machine (R) and no-load current (I0):
Pk = P0 - PS0
Ps0 = 1.5 · I0² · R
Tests
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Pk is the sum of the friction and windage losses (Pfw) and the iron losses (Pfe).
● The friction losses Pfw are determined from the no-load characteristic by extrapolating the
Pk graph to voltage 0 V.
881t,$3N:,$3N:
Figure 3-37 Determining the friction losses from the no-load characteristic
● The iron losses at the required load point are determined from the no-load characteristic
at the voltage reduced by the ohmic voltage drop in the primary winding Ui:
Pfe = P0 - Ps0 - Pfw
8 8y,y5yFRV˳,y5yVLQ˳
L
Load-dependent stator winding losses Ps
The stator winding losses, which are not corrected to the reference coolant temperature, are
determined for each load point with the values for current I and winding resistance R associated
with the specific load point.
Ps = 1.5 · I² · R
The temperature of the coolant is taken into account for each load point using factor kθ:
Ps,θ = Ps · kθ
kθ = (235 + θw + 25 - θc) / (235 + θw)
Rotor winding losses Pr
The rotor winding losses Pr, which are not corrected to the reference coolant temperature, are
determined for each load point:
Pr = (P1 - Ps - Pfe) · s
The following equation is used to correct them to the reference coolant temperature:
Pr,θ = (P1 - Ps,θ - Pfe) · sθ
Here, sθ = s · kθ is the slip, corrected to a reference temperature of 25 °C.
Load-dependent supplementary losses - PLL measured
The residual (secondary) losses PLr are determined for every load point from the load
characteristic according to the following equation:
Tests
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Reference Manual 05/2018 105
PLr = P1 – P2 - PS,θ - Pr,θ - Pfe – Pfw
P2 = 2π · T · n
The residual losses are entered over the square of the associated torque. An approximation
function is applied through the points that have been determined:
PLr = A · T2 + B
By shifting this function in parallel through –B at the coordinate origin, a function is obtained
to determine the load-dependent supplementary losses for each load point with torque M.
PLL = A · T2
3/U3//7t3/U $7t%%3// $7t
● Measured values
A Gradient
Figure 3-38 Smoothing the residual loss data
The correlation coefficient as measure of the linear interrelationship between residual losses
at the particular load points must have the following absolute value:
IEC 60034-2-1 ≥0.95
IEEE 112 method B ≥0.9
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Load-dependent supplementary losses - PLL assumed
The load-dependent supplementary losses PLL can be assumed. Depending on the rated motor
power, according to IEC 60034-2-1, the supplementary losses are obtained from the following
equations:
● For 1 kW < P2 < 10 000 kW, PLL is = P1 · [0.025 - 0.005 log 10 (P2/1 kW)]
● For P2 ≥ 10 000 kW, PLL is = P1 · 0.005
● According to IEEE 112 Method E1, the assumed supplementary losses are listed in the
following table as a function of the rated motor power:
Motor rated power [kW] Assumed supplementary losses [%]
1 ... 90 1.8
91 ... 375 1.5
376 ... 1850 1.2
1851 and more 0.9
Result
The result is confirmed in a 3.1 certificate – or in the case that the customer has ordered the
acceptance test, in a 3.2 certificate.
Tests
3.2 Additional tests
SIMOTICS 1L, 1M, 1P, 1R, 1S, 1N
Reference Manual 05/2018 107
3.2.2.16 Calculation of moment of inertia using the coast-down method
Fundamentals
The moment of inertia is required to calculate dynamic processes, for example:
● Acceleration times
● Torque oscillations
● Surge torques of a machine or a machine set.
The speed is measured over time for the coast-down method.
Test procedure
1. The machine is accelerated to approximately 110% of the rated speed by increasing the
frequency or via a coupled drive machine and is then shut down.
2. As the machine coasts down, the speed is recorded over time.
QUSP
WV
Figure 3-39 Example of a coast-down curve for speed over time
The moment of inertia is calculated based on the speed differentiation and the losses related
to speed. The deceleration losses are calculated separately for the relevant speeds, usually
at a no-load speed of n0.
˭- 35QyQ˂W˂Qyy
J = Moment of inertia
PR (n0) = Friction losses at no-load speed
n0= No-load speed
When coasting down with a coupled drive machine, the motor's moment of inertia is calculated
by subtracting the moment of inertia from the drive machine.
Tests
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Result
The test is confirmed in a 3.1 certificate – or in the case that the customer has ordered the
acceptance test, in a 3.2 certificate.
See also
Recording the no-load characteristic and calculating losses separately (Page 96)
3.2.2.17 Sealed Winding Conformance Test
Fundamentals
● API 4th edition: 4.3.4.4
● API 5th edition: 6.3.4.4
Checking the winding insulation corresponds to the subsequently described "Testing the
winding insulation (Page 109)".
3.2.2.18 Testing the winding insulation
Fundamentals
A rugged winding insulation with respect to humidity and moisture guarantees safe and reliable
machine operation at the appropriate ambient conditions. Water with low surface tension is
used to verify that the insulation is sealed according to NEMA MG1‑2003, Part 20.18.2. As a
result of their size, the stator laminated cores with winding are sprayed with water and are not
completely immersed in water.
Test equipment
● Insulation resistance measuring instrument (500 V test voltage)
● High-voltage test instrument (AC, 50 Hz)
Tests
3.2 Additional tests
SIMOTICS 1L, 1M, 1P, 1R, 1S, 1N
Reference Manual 05/2018 109
Test procedure
1. The insulation resistance of the winding is measured at a voltage of 500 V. It is not
permissible that the insulation resistance falls below 1500 MΩ.
2. The winding, especially the winding overhangs, are sprayed with water for 30 min. The
water properties are adjusted to obtain a surface tension of 31 x 103 mN/m.
Figure 3-40 Spraying the winding
3. The insulation resistance is measured for 10 minutes at a voltage of 500 V immediately
after spraying. The minimum insulation resistance in MΩ must reach 5 · UN + 5 (UN in kV).
4. The winding that is still wet is subject to an AC voltage test with 1.15 · UN for 1 min.
5. The insulation resistance is measured again for 1 min. The minimum insulation resistance
in MΩ is also 5 · UN + 5.
6. The stator laminated core with winding is cleaned and dried before it is used further.
Result
The test has been successfully completed if the insulation resistance reaches the minimum
values - and the AC test voltage is maintained during the test duration of 1 min.
All test results are recorded in a test certificate. The successful test is confirmed in a 3.1
certificate – or in the case that the customer has ordered the acceptance test, in a 3.2 certificate.
3.2.3 Material Inspection
Fundamentals
● API 4th edition: 4.2.2
● API 5th edition: 6.2.2
Tests
3.2 Additional tests
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The aim of the material inspections is the detection of material faults, such as cavities, cracks,
pores, inclusions, etc – and to document the material quality. Material inspections are
completed during production or are part of the incoming goods inspection.
The material inspections are completed on fully machined parts following the last relevant heat
treatment for the material properties. Normally, the shaft or, for example, the weld joints on
the the bar shaft are tested.
The test personnel are to be certified according to EN 473 to at least Level 1, the test
supervision personnel to at least Level 2.
See also
Radiographic Test Parts (Page 111)
Ultrasonic Test (Page 112)
Magnetic Particle Test Parts (Page 115)
Liquid Penetrant Test Parts (Page 116)
3.2.3.1 Radiographic Test Parts
Fundamentals
● API 4th edition: 4.2.2.2
● API 5th edition: 6.2.2.2
● ISO 5579 or EN 444 in test Class B. EN 12681 is applicable for radiographic testing of cast
parts.
The permissible limits are specified in the drawing or in the test plan.
The X-ray test identifies internal flaws in the component that are not permissible. The test is
carried out after the last heat treatment that is key to the material properties. The surfaces of
the components to be checked must be free of impurities.
The number and size of the permissible faults within the respective acceptance levels to be
observed - also "Quality levels" or "Quality classes" - are described as follows:
● Cast parts:
– ASTM E 446 for cast steel
– ASTM E 155 for aluminum and magnesium-cast parts
● Welded constructions:
– ISO 6520‑1 to classify any irregularities
– ISO 5817 for appraisal groups for the irregularities
● Forged parts: Based on ASTM E 446
Tests
3.2 Additional tests
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Reference Manual 05/2018 111
Test equipment
The following and additional test equipment can be used:
● X-ray device Isovolt 320 from the company Seifert. Voltage class 320 kV, max. ray flow
13 mA, focal spot 2 mm2
● Microfocus rod anodeXWT‑225‑RAC made by X-RAY WorX GmbH voltage class 225 kV,
max. tube current 1 mA, focused spot < 6 µm
● X-ray films in film classes C3 or C4 according to EN 584-1 with lead reinforcement films,
i.e. front and back film, each with 0.02 mm lead
The required image quality of the x-rays is to be documented with image quality test
specimens to EN 462-1 to -5. The radiograph density is in the range that can be analyzed
for test class A ≥ 2.0 and test class B ≥ 2.3.
Test procedure
1. Each film is uniquely identified by lead numbers.
2. The film location on the component, if necessary, is added as a film location plan to the
test report to enable a precise reconstruction of the images.
– Overlapping zones are marked by attaching lead points.
– X-rays after completed repairs are also marked with "R".
3. The components are x-rayed.
Result
If requested, a test report in accordance with EN 444 is produced for each performed test.
3.2.3.2 Ultrasonic Test
Fundamentals
● API 4th edition: 4.2.2.3
● API 5th edition: 6.2.2.3.2
The ultrasonic test identifies internal flaws in the component that are not permissible.
A suitable coupling device is used for all ultrasonic tests. Distance and sensitivity adjustment,
and the testing sequence are completed with the same coupling aid. The distance and
sensitivity adjustment is carried out in accordance with EN 583‑2. Displays that require
registration must cover 20% of the height of the screen.
Tests
3.2 Additional tests
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Figure 3-41 Example: Ultrasonic display in an A screen with flaw echoes ①
Test equipment
The test is carried out with test equipment in accordance with EN 12668‑1 to ‑3.
The probes are selected depending on the material and diameter of the shaft blanks. The
following ultrasonic probes are used:
Table 3-7 Ultrasonic probes
Probe Angle Frequency Diameter of the transducer
Vertical probe 0° 2 MHz 10 mm or 24 mm
Vertical probe 0° 4 MHz 10 mm or 24 mm
Vertical probes with separate
transmitter and receiver (SE
test probes)
0° 2 MHz 10 mm or 24 mm
Result
A test report in accordance with EN 583‑1 is created for each of the ultrasonic tests
subsequently described.
Ultrasonic test of rolled or forged shaft blanks
Fundamentals
The ultrasonic test is carried out according to EN 10308 and EN 10228‑3. The test is performed
on the shaft blank after the last heat treatment relevant for the material properties. The surface
of the shaft blank must be free of scale; the quality of the surface must comply with the quality
grade 3 according to EN 10228-3.
The DGS method is completed on the specimen, as part of the sensitivity adjustment. DGS
means: D = distance, G = gain, S = replacement reflector size.
For this purpose, the provided DGS diagrams for the appropriate probes are used. A DGS
diagram shows the echo amplitudes of the so-called circular disk reflectors of various
diameters and of a large plane reflector (rear panel) as function of the distance.
Tests
3.2 Additional tests
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Test procedure
The test is carried out using the manual pulse-echo contact technique. During this process,
the sample rate must not exceed 150 mm/s.
100% of the peripheral surface is checked, whereby the test paths overlap by at least 10% of
the effective diameter of the probe. When scanning at only 180°, the same test area is also
checked with a TR probe to record areas near the surface.
The registration limit corresponds to the permissible limit. The permissible limits apply to
individual punctiform discontinuities and grouped discontinuities. Extended discontinuities are
not permissible.
Table 3-8 Permissible limit depending on the shaft diameter
Shaft diameter Permissible limit
≤ 150 mm Flat bottom hole FBH = 2 mm
> 150 mm Flat bottom hole FBH = 3 mm
Ultrasonic test of welded products
Fundamentals
The ultrasonic testing of weld joints is carried out in accordance with ISO 17640. The test
category is selected in accordance with the evaluation group specified in the drawing or the
test plan according to ISO 5817.
Test procedure
The test is carried out using the manual pulse-echo contact technique. During this process,
the sample rate must not exceed 150 mm/s.
The permissible limits must be observed in accordance with ISO 11666.
Table 3-9 Permissible limit depending on the shaft diameter
Shaft diameter Permissible limit
≤ 150 mm Flat bottom hole FBH = 2 mm
> 150 mm Flat bottom hole FBH = 3 mm
Ultrasonic testing of cast parts
Fundamentals
The ultrasonic testing of cast parts is carried out in accordance with the following standards:
● EN 12680‑1 for steel cast parts for general use
● EN 12680‑2 for steel cast parts for highly stressed parts and components
● EN 12680‑3 for castings made of cast iron with nodular graphite
The applicable quality grades are specified in the drawing or the test plan.
Tests
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Test procedure
1. The test is carried out using the manual pulse-echo contact technique. During this process,
the sample rate must not exceed 150 mm/s.
The applicable registration and permissible limits must be observed in accordance with
EN 10228-3.
3.2.3.3 Magnetic Particle Test Parts
Fundamentals
● API 4th edition: 4.2.2.4
● API 5th edition: 6.2.2.4
The magnetic particle test is carried out according to ISO 9934‑1 bis ‑3. EN 1369 applies to
the magnetic particle test on ferromagnetic iron and steel cast parts.
The test identifies all possible inhomogeneities in the material. Combined magnetization is
used to verify the inhomogeneities in all directions. The bare load locations of the cast iron
enclosure are tested.
Note
Non-ferromagnetic layers up to 50 µm, such as non-destroyed, flat fixed color layers, do not
influence the sensitivity of detection. The sensitivity of detection is verified for thicker layers.
The number and size of the permissible material faults within the respective acceptance levels
to be observed - also "Quality levels" or "Quality classes" - are described as follows:
● Forged parts: EN 10228‑1
● Welded constructions: ISO 23278
● Cast parts: Based on EN 10228‑1
Type Damage Quality class
I Material separations 1
II Shrinkage 2
III Inclusions 2
IV Scales and peeling 1
V Porosity 1
VI Welds 1
Test equipment
The test solution used meets the requirements of ISO 9934-2. The test solution is a suspension
made from fluorescent particles in a carrier liquid.
Tests
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Reference Manual 05/2018 115
Test procedure
Before starting the test, the entire test system is checked.
1. The surface is cleaned.
2. The test solution is applied before and during the magnetization of the component. The
application of the test solution is terminated before switching off the magnetization.
3. The result is assessed. The evaluation conditions fulfill the requirements according to
ISO 3059. All indications that cannot be clearly identified as false indications are classified
and registered according to the requirements of the product standard:
– Line-shaped: Length is greater than three times the width
– Round: Length is equal to or less than three times the width
4. If agreed, the test specimen is demagnetized after the check, so that the agreed remaining
field strength is reached. The parts are cleaned and anticorrosion protection applied.
Result
The permissible limits are specified in the drawing or in the test plan. A report is to be produced
for each test carried out pursuant to EN 9934-1 in German / English, if requested.
3.2.3.4 Liquid Penetrant Test Parts
Fundamentals
● API 4th edition: 4.2.2.5
● API 5th edition: 6.2.2.5
● ISO 3452‑2 to ‑6 and EN 571‑1
The liquid penetrant test identifies external flaws in the component surface for solid and spider
shafts etc., which are not permissible. The test is carried out after the last heat treatment - that
is key to the material properties - at the machined part. The surfaces must be of a condition
that corresponds to the test purpose. They must be free of scale, spatter or other loose dirt.
Scoring, scars, etc. that adversely affect the test result are not permissible.
The number and size of the permissible markings within the respective acceptance levels to
be observed - also "Quality levels" or "Quality classes" - are described as follows:
● Forged parts: EN 10228‑3
● Cast parts: EN 1371‑1
● Welded constructions: ISO 23277
Test equipment
● Test equipment system II A d according to EN 571-1 1
● A fine-granular powder (chalk) in suspended solvents is used as developer. The capillary
action in the own cavities causes the developer to remove the remaining penetrant from
the fine cracks or cavities. This procedure is designated as developing an error display, in
short, display.
Tests
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Test procedure
1. The test area is cleaned. It must be dry, clean and free of oil, grease and other any dirt.
2. The penetrant is applied by spraying, painting or dipping. The temperature of the test
surfaces lies in the range between 5 °C to 50 °C.
The penetration duration is 30 min. During this time it is ensured that the penetrant does
not dry.
3. The penetrant is removed by rinsing, spraying or wiping with water. Sharp spraying is not
permitted. Warm water may be used as long as the water temperature is not higher than
50° C.
4. Immediately after intermediate cleaning, the test surfaces are dried.
5. The developers are applied evenly by spraying immediately after drying. The test surfaces
are kept vertical where possible; they are then covered evenly with developer.
The development term matches the penetration term of 30 min. In exceptional cases, the
development term may also be extended.
6. The result is evaluated after the developer has been applied or after it has dried. The
relevant assessment of the displays for the evaluation is performed after expiration of the
development duration.
7. After the last evaluation, the tested part must be cleaned if residues from the test equipment
could impair its further use.
Result
The permissible limits are specified in the drawing or in the test plan. A test report in accordance
with EN 571-1 is created for each performed test.
3.2.4 Other tests
3.2.4.1 Coordination Meeting
Fundamentals
● API 5th edition 8.2
At the kickoff meeting ("Coordination Meeting") based on the confirmed ordering data, the
implementation of all order-related components is discussed and checked. The date
represents a hold point for the start of production.
Preconditions
● The order must have been entered into the factory.
● The technical clarification must have been completed. Only then can a date be defined for
the kickoff meeting.
Tests
3.2 Additional tests
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The group of participants is restricted as follows:
● Siemens customer, representative from the region and possibly representatives from
additional partners in the supply chain (representatives from "Engineering, Procurement
and Construction" (EPC), third party, end user)
● Internal Siemens engineering
● Manufacturer of the converter system
Workflow
The following topics can be discussed:
● The region places an order with the factory, contact person in the factory, area of
responsibility, responsibilities, documents and purchased parts, communication paths
● Required contractual data and data sheets according to API 541
● Factory data: Order number of the region, order number of the factory, order number of the
motor (MLFB) - or where relevant - the TAG number of the motor
● Spare parts with the associated order numbers, list of recommended spare parts → Manual
● Comments and deviations to API 541 and project
● Speed-torque characteristic and moment of inertia of rotating parts → electrical
documentation
● Schedule for transferring data for the production workflow, testing and shipping
● Production schedule, if one of the options B43, B44 or B45 was ordered.
● Quality management manual, ISO 9001 certification
● Operating conditions and corresponding restrictions relating to the motor → electrical and
mechanical documentation
● Instrumentation, operating elements and additional motor interfaces → Information about
the machine dimension drawing
● Applications, performance, operating parameters, piping and instrument flowchart for
auxiliary systems → information on the machine dimension drawing
● Identification of components, which require a design review. It is possible that only certain
information is available at this point in time, e.g. shaft design, motor dimension drawing,
information about the machine dimension drawing, position data, geometry
● Inspection, test procedures and the appropriate acceptance criteria
● Additional technical points. The basis is the electrical and mechanical technical
documentation and/or the machine manual and the test description.
3.2.4.2 "Design Review"
Fundamentals
● API 4th edition: 6.2.1.4
● API 5th edition: 8.4
Tests
3.2 Additional tests
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Based on the confirmed ordering data, after the electrical and mechanical engineering process,
an internal design review is carried out where the use of new order-related components is
checked.
3.2.4.3 Submit Test Procedures 6 Weeks Before Tests
Fundamentals
● API 4th edition: 4.3.1.5
● API 5th edition: 6.3.1.4
Six weeks before the final electrical test, the customer receives an order-specific description
of the tests that are conducted as standard for this motor and possible optional tests – and a
function test plan if tests are to be conducted.
List of documents and information
The documents referred to in the following are supplied only when they are part of the contract
or explicitly ordered.
1. Type of the test (electrical or mechanical)
2. Sequence of the tests
3. Schedule of the test sequence
4. Contractually agreed values:
– Temperature rise
– Vibration
– Critical speeds
– Efficiency
– Noise
5. Alarm and trip values
6. For converter-supplied motors:
– Base frequency at which the test is completed
– Harmonic content
7. List of the measuring equipment used
Note
Customer information
Some of the content is dependent on information that the customer must provide, such as the
coupling drawing for the lateral analysis. The test description can only be transferred in full
when all of the content is available.
Note
Empty test report forms are not handed out in advance.
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Additional documents
● List of test measuring instruments and calibration process as separate document.
The customer receives a list including the measuring device, type, and manufacturer,
additional information at the time of the next calibration and registration number.
Can be ordered separately
Depending on the order, the customer will also receive the following:
● Rotor-dynamic calculations
For these calculations, the customer must provide a drawing of the coupling on time.
● Drawings and parts lists for the spare parts list (option B38)
A spare parts recommendation is only provided if it is specifically ordered.
● Calibration certificates for the measuring instruments at the machine.
All of the existing data sheets, test certificates or calibration reports are sent to the customer
assuming that they are available at the time.
The operating instructions or the collection of certificates created after the delivery contains
all of the documents. If information is required in the meantime, this is agreed with the
customer.
3.2.4.4 Shop Inspection
Fundamentals
● API 4th edition: 4.1.1
● API 5th edition: -
With the shop inspection, customers have the opportunity of obtaining a general overview of
the most important production areas.
Note
This preinspection does not constitute a witness test or a holding point in production. The
customer cannot ask for production to be stopped following a pre-inspection.
If the customer requests order-related information or supplements to be taken into
consideration, their feasibility will be checked. The customer will be informed about the result
of this verification.
Workflow
Once the order has been clarified technically, the customer is invited to complete a general
pre-inspection of the coil winding workshop, assembly and system test facility or test field.
Other production areas are not included in the scope of the pre-inspection.
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3.2.4.5 Demonstrate Accuracy of Test Equipment
Fundamentals
● API 4th edition: 4.3.1.14
● API 5th edition: 6.3.1.15
The customer receives full proof of the test configuration accuracy based on the calibration
certificates.
Calibration certificate
Each calibration certificate describes the calibration item, calibration procedure, measurement
uncertainties and ambient conditions.
Calibration process
The calibration process is documented by the following specifications:
● Measuring range
● Condition
● Setpoint
● Actual value
● Permissible deviations
● Measurement uncertainty
● Evaluation of the measurement
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Figure 3-42 Example of a calibration certificate
3.2.4.6 Stator Inspection Prior to VPI
Fundamentals
● API 4th edition: 4.3.4.5
● API 5th edition: 6.3.4.5
Prior to impregnation, a visual acceptance of the winding that is fully inserted and connected
in the laminated stator core is carried out.
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Result
The certificate can also include the data and results from the preliminary test, i.e. visual
inspection, dimensional check, electrical testing. The test result is documented in a 3.1
certificate – or in the case that the customer has ordered the acceptance test, in a 3.2 certificate.
3.2.4.7 Sound pressure level test
Fundamentals
Unless other customer requirements apply, the noise measurement is performed on the basis
of ANSI/NEMA MG-1 Part 9 in accordance with ISO 3744 and ISO 1680. The measurement
is performed in accordance with accuracy class 2.
The measurement verifies that possibly applicable limit values are complied with.
Note
Limit values
The limit values from the respective catalog serve as reference values for evaluating the noise
measurement. In the event of unexpected individual noises, such as magnetic sounds, sirens,
etc., an additional noise analysis can be performed.
Further, it may be necessary to make modifications at the motor for example, to check the
effect of the changes regarding the noise emission. The noise measurement is performed in
the following situations:
● When required by the customer or purchaser
● For new motors as part of the type test
In order to clarify the causes of noise, especially of individual tones, additional frequency
analyses can be carried out.
Test equipment
● Measuring systems in accordance with ISO 3744 based on IEC 61672-1:2002 Class 1 with
valid calibration are used
● A "wind shield" manufactured out of foam is used in front of the microphone. This stops
noises from the draft falsifying the measurement result.
Measuring procedure
The noise measurement is performed in no-load operation at the rated voltage and rated
frequency. The thermal state the machine is not relevant. The sound pressure level is
calculated on an A-weighted basis.
1. The sound pressure level of the machine noise is recorded at each measuring point.
2. Every measured sound pressure level is corrected by applying correction factors K1
(external noise) and K2 (to take into account the acoustic profile of the room).
The noise levels can also be measured in an acoustic measuring chamber. In this case,
the correction factor for external noise is not applied.
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3. The corrected sound pressure levels are averaged, resulting in the measuring-surface
sound pressure level.
4. The sound power level LWA is calculated from the following relationship:
LWA =
/SI$
+ 10 log (S/1m2)
LWA = A-weighted sound power level
/SI$
= A-weighted measuring-surface sound-pressure level
S = measuring surface in m2
Result
The measurement report contains the following data:
● Motor dimensions
● Position and the number of measuring points according to the motor dimensions
● Measuring conditions, such as used measuring equipment and where relevant, external
noise
● Background noise correction value
● Measuring-surface sound-pressure level
● Measuring-surface sound-power level
3.2.4.8 Noise analysis
Fundamentals
A noise analysis can be performed at the request of the customer or if unexpected individual
noises occur, such as magnetic sounds, sirens, etc.
The noise analysis is performed even if a third octave or octave spectrum of the machine noise
is required. Based on a third octave or octave spectrum, for example, active or passive noise
reduction measures can be applied.
Test procedure
1. Octave and third-octave frequency spectrums recorded on the measuring path 1. The
number of measuring points depends on the machine size and the radiation characteristics.
If the frequency spectrum is only measured at one measuring point, then a point is selected
where the average sound pressure level exists.
2. Additional external noise profiles can be measured depending on the equipment available
in the test field.
– If the external noise over the complete third-octave medium-frequency range has >
15 dB distance to the A-weighted measured values, the external noise is measured only
at a representative measuring point; K1 = 0 dB.
– If the external noise over the complete third-octave medium-frequency range has
< 15 dB distance to the A-weighted measured values, the external noise is measured
at every measuring point.
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Result
The results are provided in different forms depending on the particular factory:
● In Ruhstorf, the report includes the measured measuring-surface sound pressure level in
the octave spectrum fOctave in a graphic form.
● In Nuremberg, the report contains the measured measuring-surface sound-pressure levels
and measuring-surface sound-power levels in the third-octave spectrum fthird-octave in tabular
and graphic form.
As documentation of the test result, a 3.1 certificate is issued, or for acceptance tests witnessed
by the customer, a 3.2 certificate is issued.
See also
Sound pressure level test (Page 123)
3.2.4.9 Function test at the test field converter
For this test, the motor is tested together with the test field converter.
● High-voltage motors connected to SINAMICS Perfect Harmony GH180
● Low-voltage motors connected to SINAMICS S120
Basic scope of the function test
1. Measuring the resistance of the stator winding (Page 35) when cold
2. Temperature rise test (Page 79) at the rated operating point
3. Measuring the resistance of the stator winding (Page 79) when warm
4. Load test (Page 99) at four operating points (speed, torque)
Load points
1. Temperature rise test under load
2. The following parameters are measured at different speeds at each load point:
– Converter output frequency
– Motor current, motor voltage
– Motor speed
– Torque and power at the motor shaft
Motor high-voltage test
A motor high-voltage test is already part of the test; however, it can be repeated as part of the
system test.
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Visual inspection
● Visual inspection of motor
Noise measurement at the motor
The noise is only measured with option F28/F29 or F62/F63.
1. The motor is operated at the converter and at rated speed without any load.
2. The sound pressure level of the machine is recorded at defined measuring points. The
sound pressure level is calculated on an A-weighted basis.
Vibration test at the motor
1. The motor is operated at the converter and at rated speed without any load.
2. The vibration velocities are measured for the rated voltage and frequency at the bearing
housing.
3. For sleeve bearings, the shaft vibration is also measured if the appropriate transducer is
mounted.
See also
Component test (Page 32)
Time required (Page 33)
3.2.4.10 Certified data prior to shipment
Basis
● API 5th edition 8.6.2a
After the motor has been produced and tested, the manufacturer provides all of the agreed
certificates ("Certified data prior to shipment"). Depending on the archiving guidelines, every
document is archived for a specific time.
A separate meeting can be arranged for requirements relating to packaging and shipping,
where details can be discussed and agreed on.
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3.2 Additional tests
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Index
A
API 2.4.6.3.3, 72
API 2.4.6.3.6, 66
API 4.1.1, 120
API 4.1.5, 65
API 4.2.1.1e, 67
API 4.2.2, 110
API 4.2.2.2, 111
API 4.2.2.5, 116
API 4.2.3.2, 67
API 4.2.3.3, 67
API 4.3.1.14, 121
API 4.3.1.5, 119
API 4.3.2.1h, 59
API 4.3.2.1j, 68
API 4.3.2.1k, 70
API 4.3.3.12, 70
API 4.3.3.2, 39
API 4.3.4.2, 54
API 4.3.4.2.1, 92
API 4.3.4.5, 122
API 4.3.5.4, 75
API 4.4.6.3.4, 66
API 4.4.9.4, 72
API 4th edition, 23
API 5th edition, 23
API 6.2.1.1e, 67
API 6.2.1.4, 118
API 6.2.2, 110
API 6.2.2.2, 111
API 6.2.3.3, 67
API 6.2.5.1a, 66
API 6.3.1.15, 121
API 6.3.1.16, 37
API 6.3.1.4, 119
API 6.3.1.5, 72
API 6.3.2.1h, 59
API 6.3.2.1k, 68
API 6.3.2.1l, 70
API 6.3.3.4, 39
API 6.3.4.1, 90
API 6.3.4.2, 54
API 6.3.4.2.1, 92
API 6.3.4.3, 90
API 6.3.4.4, 109
API 6.3.4.5, 122
API 6.3.4.6, 94
API 6.3.5.3, 74
API 6.3.5.4.1, 75
API 6.3.5.6, 65
API 8.2, 117
API 8.4, 118
API 2.4.6.3.1a, 66
API 4.2.2.3, 112
API 4.2.2.4, 115
API 4.2.2.5, 116
API 4.3.1.15, 37
API 4.3.1.6.2, 72
API 4.3.2.1i, 60
API 4.3.3.1, 52
API 4.3.4.1, 90
API 4.3.4.3, 90
API 4.3.4.4, 109
API 4.3.5.2.1, 43
API 4.3.5.3, 74
API 6.2.2.3.2, 112
API 6.2.2.4, 115
API 6.2.2.5, 116
API 6.3.2.1j, 60
API 6.3.3.5, 78
API 6.3.5.2.1, 43
API 8.6.2a, 126
B
B29, 77
Balance quality of the motor components, 66
Bearing Dimensional & Alignment Checks After
Tests, 70
Bearing Dimensional & Alignment Checks Before
Tests, 68
Bearing Housing Natural Frequency Tests, 75
Bearing Inspection After Tests, 60
Bearing inspection before the electrical tests, 68
Bearing temperature rise, 59
C
Calculating the efficiency from the individual
losses, 103
Calculating the moment of inertia using the coast-
down method, 108
Certified data prior to shipment, 126
Checking the precision of the balancing machine, 66
Cleanliness test, 67
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Combination test - Complete Test, 21
Combination test F82 / F83, 18
Component balance, 66
Components provided by customer, 12
Coordination meeting, 117
Customer acceptance inspection, 12
D
Demonstrate Accuracy of Test Equipment, 121
Design review, 119
Detection of resonance effects in the bearing
housing, 75
F
F03, 77
F04, 79, 83
F05, 79, 83
F100, 38
F103, 119
F104, 117
F106, 120
F107, 119
F108, 67
F109, 67
F110, 67
F111, 78
F112, 78
F113, 78
F114, 121
F115, 121
F116, 121
F117, 90
F118, 90
F119, 90
F120, 54
F121, 54
F122, 54
F123, 92
F124, 92
F125, 92
F126, 66
F132, 66
F133, 66
F134, 66
F135, 73
F136, 73
F137, 73
F138, 65
F139, 122
F14, 96
F140, 122
F141, 122
F142, 109
F143, 109
F144, 109
F145, 87, 90
F148, 68
F149, 68
F15, 96
F150, 68
F151, 70
F152, 70
F153, 70
F154, 21, 44, 79, 98, 101, 102, 103, 123
F155, 21, 44, 79, 98, 101, 102, 103, 123
F156, 21, 44, 79, 98, 101, 102, 103, 123
F157, 123
F158, 123
F159, 123
F16, 98
F160, 70
F166, 74
F167, 74
F168, 74
F169, 75
F17, 98
F170, 75
F171, 75
F172, 67
F176, 126
F178, 111
F18, 99
F181, 111, 112, 113, 114
F184, 111, 112, 113, 114
F185, 111, 115
F186, 111, 115
F187, 111, 115
F188, 111, 116
F189, 111, 116
F19, 99
F190, 111, 116
F191, 44
F192, 44
F193, 44
F20, 103
F21, 103
F22, 86
F23, 86
F26, 87
F28, 123
F29, 123
Index
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F34, 102
F35, 102
F36, 108
F37, 108
F38, 65
F39, 65
F42, 109
F43, 109
F46, 94
F52, 101
F53, 101
F54, 49
F55, 49
F58, 71
F59, 71
F60, 92
F61, 92
F62, 124
F63, 124
F67, 60
F71, 52
F74, 25, 79, 99, 125
F75, 25, 79, 99, 125
F82, 79, 98, 103
F83, 79, 98, 103
F92, 79, 98, 103
F93, 79, 98, 103
F97, 25
Final Assembly Running Clearances, 67
Function test according to API 541, 20
Function test according to IEC, 17
Function test at the test field converter, 125
Function test of the drive system, 31
Function test schedule and test descriptions six
weeks before the final electrical test, 119
H
Heat exchanger function test, 78
Heat exchanger performance verification test
TEWAC, 78
High-voltage test, 31
Hydrostatic test, 79
I
Impulse voltage withstand test carried out at
individual coils, 92
Inspection for cleanliness, 67
Inspection of the laminated stator core with the
winding prior to impregnation, 122
Insulation test, 31
K
Kickoff meeting, 117
L
Liquid penetrant test, 116
Liquid Penetrant Test, 116
Load points and determining the system
efficiency, 31
Loss factor and capacitance measurement at the
complete winding or machine, 87
Loss factor measurement, 90
M
Magnetic particle test, 115
Magnetic Particle Test Parts, 115
Material inspection, 111
Material inspections, 111
Measurement of harmonics, 31
N
Noise analysis, 124
Noise measurement, 32
Noise measurement under no-load conditions, 123
O
Overspeed test, 65
P
Paint thickness measurement, 77
Partial discharge measurement at the winding/
machine, 94
Partial discharge test, 94
Pneumatic routine test, 27
Pneumatic type test, 27
Polarization index, 50
Power factor tip-up test, 87, 90
Pre-inspection of the production environment, 120
Proof of the accuracy of the test setup, 121
Purging and dilution test, 28
Index
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R
Radiographic test, 111
Recording the current and torque characteristics
using a dynamometer, 102
Recording the frequency spectrum, 70
Recording the load characteristic, 99
Recording the no-load characteristic and calculating
losses separately, 96
Recording the short-circuit characteristic and short-
circuit losses, 98
Recording the starting torque and current, 101
Residual unbalance verification test, 66
Ring core magnetization, 90
Routine test, 17, 35
Agreement between the direction of rotation and
terminal designations, 36
Air gap measurement, 52
Bearing insulation measurement according to
API, 51
Bearing temperature rise, 59
Converter, 15
DC resistance test of the stator winding, 35
Flow rate measurement and adjusting the
pressurized system, 63
High-voltage test, 55
Leakage loss measurement of motors with type of
protection Ex px, 61
Leakage test for water-cooled motors, 64
Measurement of the polarization index, 49
Measuring the insulation resistance, 46
Motor, 15
No-load test, 36
Pressure distribution measurement at motors,
type of protection "device protection provided by
pressurized enclosure"., 62
Runout measurement with acceptance, 52
Shaft voltage measurement, 51
Shock pulse measurement, 57
Short-circuit test, 36
Slow roll measurement according to API, 53
Soft Foot test, 38
Testing accessories, integrated and mounted
components, 45
Transformer, 15
Vibration severity measurement, 38
Vibration severity measurement according to API
541, 39
Vibration severity measurement for Complete
Test, 44
Visual sleeve bearing inspection after the
electrical tests, 60
Voltage test of the main insulation while the
windings are being produced, 56
Winding test carried out while the winding is being
manufactured, 54
Withstand voltage test, 37
Running/vibration tests with coupling half, 73
S
Sealed Winding Conformance Test, 109
Shop inspection, 120
Short-circuit temperature rise test for motors with type
of protection Ex e, 84
Sleeve bearing inspection after the electrical
tests, 70
Sound pressure level test, 123
Special Surge Test of Coils, 92
Spray test, 109
Stator Core Test, 90
Stator inspection prior to VPI, 122
Submit Test Procedures 6 Weeks Before Tests, 119
System acceptance test, 33
System test, 29
T
tan δ loss factor measurement at single coils, 86
Temperature rise test under load, 27, 29, 79
Test certificates and component certificates, 126
Test that components and parts are free to move, 67
Testing the temperature limits of components in
explosion-protected motors, 83
Testing the winding insulation, 109
Type test, 28
U
U85, 77
Ultrasonic test, 112
of cast parts, 114
of rolled or forged shaft blanks, 113
of welded products, 114
Ultrasonic Test Parts, 112
Unbalance response test, 74
V
Vibration analysis, 71
Index
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Index
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132 Reference Manual 05/2018
Further Information
www.siemens.com/drives
Siemens AG
Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
