CUSTOMER'S GUIDE

Large AC Motor Testing

At

Kings Mountain N.C.

Plant
 TABLE OF CONENTS

Reference Number Test Completed

1 Ac Hi-pot Test
2 Bearing Inspection
3 Bearing Insulation Test
4 Bearing Run For API Motors
5 Bracket Natural Frequency Test
6 Check Test With Customer
Supplied Coupling
7 Dc Hi-potential Test
8 Dynamometer cold to hot
uncoupled vibration test
9 Heat Run
10 Locked Rotor Saturation
11 No Load Saturation
12 Noise
13 Overspeed Unbalanced
Coastdown
14 Performance (method B)
15 Performance (method F)
16 Polarization Index
17 Routine Mechanical Run Test
18 Routine Test - Standard
19 Setup Guidelines For API
Testing
20 Speed Torque
21 Stator Core Test
22 Stator Winding Immersion
1. AC HI-POT TEST
Reliance Specification: 46101 Section 10
Industry Specification: IEEE 112-9.2, NEMA MG-20.17
Location: Hi-pot tester
Purpose: Verify the integrity of the insulation.
Procedure: 1) Apply a voltage of twice rated + 1000 to the stator windings.
2) Measure and record leakage amps.
3) If applicable, apply 1000 volts to accessories.
4) Measure and record leakage amps.

2. BEARING INSPECTION
Reliance Specification: 419530-138 Part I
Industry Specification: API-541 / 547
Location: Assembly
Purpose: Verify bearing wear pattern
Procedure: 1) Perform bearing inspection on sleeve bearing motors.
2) Sketch bearing patterns and plastigage the bearing to shaft clearance
and bearing to bracket crush. Use a six (6) mil shim between the
bracket cap and bearing when plastigaging the OD of the bearing.
Reassemble the motor and continue with specified testing on sales
order.

3. BEARING INSULATION TEST

Reliance Specification: 419530-138 Part J
Industry Specification: API-541 / 547
Location: Assembly
Purpose: Verify integrity of bearing insulation system
Note: For TEFC or TEAAC motors, bearing insulation test will be
performed prior to final assembly due to construction of fan housing
components. Data and records will be provided to a Customer witness if
necessary. This test will not be performed for a Customer witness, unless it
is previously agreed to and scheduled. Witness will need to be present two
days prior to start of other tests.
Procedure: 1) List all the test equipment used for motor testing. Include equipment
description and calibration date.
2) Reassemble brackets and measure bearing insulation with a multi-
meter set on maximum ohms. The readings must show an open circuit.
4. BEARING RUN FOR API-541 3rd Edition MOTORS
Reliance Specification: 419530-138 Part B
Industry Specification: API-541 / 547
Location: Seismic Mass
Purpose: Perform bearing run on sleeve bearing motors to determine bearing
performance through measurements of bearing temperatures, vibration
and bearing contact pattern
Procedure: 1) Review all inspection records. When the motor has customer specified
proximity probes, check for probe calibration plots. If there are no
calibration records, generate calibration plots for proximity probes – 0
to 70 mil.
2) Set motor on mass per 419530-138 Part A.
3) Perform a bearing run with motor operating at rated voltage. Run the
motor for 20 minutes and measure the following:
4) Record vibration levels every minute for the 20-minute bearing run
test.
5) At the end of the 20-minute bearing run, record the ambient
temperature and the bearing temperatures.
6) c. When the motor has proximity probes record the proximity probe
run-out during the coast down at a speed between 300 and 200
rpm. Hold the shaft on magnetic center when recording slow roll run-
out.
7) Inspect the entire motor for signs of oil leakage, no leakage allowed.
8) Send motor back to assembly and perform bearing inspection.

5. BRACKET NATURAL FREQUENCY TEST

Reliance Specification: 419530-138 Part H
Industry Specification: API-541 / 547
Location: Seismic Mass
Purpose: Verify bracket natural frequency locations
Procedure: 1) If motor set-up has changed since the last test, prepare motor for
testing per Section A.
2) Ring both brackets for a resonance response in the horizontal, vertical
and axial directions. Start the motor so shaft rotation is between 200-
300 rpm when ringing brackets. Plot the frequency response from 0 -
200 Hz.
6. CHECK TEST WITH CUSTOMER SUPPLIED COUPLING
Reliance Specification: 419530-138 Part C
Industry Specification: API-541 / 547
Location: Seismic Mass
Purpose: Determine effect of customer mounted coupling on vibration performance
Procedure: 1) Note: This test is required only when the coupling balance was not
checked at the finish line.

2) Perform motor setup per 419530-138 Part A, except mount the

customer coupling on the shaft extension.
3) Start the motor and increase voltage to rated voltage. Run the motor at
rated voltage until the bearing temperatures stabilize to a 1 °C change
per 30 minutes.
4) Record vibration level in 30-minute increments throughout test
beginning at motor startup. For the last set of vibration levels, record
the vibration in one (1) minute increments for 15 minutes to generate
time plots. When there are no proximity probes provided, record only
the bracket vibration levels.
5) After the bearing temperatures stabilize reduce the voltage to ¼
voltage, hold the shaft on magnetic center and record a set of vibration
readings.

7. DC HI-POTENTIAL TEST
Reliance Specification: 419530-144
Industry Specification: API-541 / 547, IEEE-95
Location: DC Hi-Pot Tester
Purpose: May aid in predicting the condition of the stator winding. May also allow
approximate prediction of the insulation breakdown voltage. Note - IEEE
points out that there is some controversy in the interpretation of test
results.
Procedure: 1) Bleed any residual charges on the stator windings by grounding.
2) Preferably this test should be conducted when the stator winding is at
or near ambient temperature.
3) Connect the stator lead to the DC power supply. Apply voltage in not
less than four approximate equal steps, pausing one minute at each
step and five minutes at the final voltage. Maximum recommended DC
test voltage is given by the following equation: Vdc max = (2*VLL + 1) *
(1.75) * (0.75)
4) Record applied voltage, leakage current and insulation resistance.
8. DYNAMOMETER COLD TO HOT UNCOUPLED VIBRATION TEST
Reliance Specification: 419530-138 Part G
Industry Specification: API-541 / 547
Location: Load Stand
Purpose: The Cold to Hot Uncoupled Test verifies rotor vibration stability between
cold operating conditions and when the rotor reaches operating
temperature. The cold to hot vibration levels takes out any vibration
associated with misalignment or vibration transmitted from the gearbox
and provides vibration data only on the motor characteristics.
Procedure: 1) Align the motor to the dynamometer with a spacer in the coupling.
2) Prepare motor for test per 419530-138 Part A.
3) Uncouple the motor. Run the motor uncoupled at rated voltage and at
rated speed for 1 hour after the bearing temperatures stabilize to 1°C
change per 15 minutes.
4) Record the bearing and stator winding temperatures in 15-minute
increment.
5) Record vibration level in 30-minute increments throughout test,
beginning at motor startup. When there are no proximity probes
provided record only the bracket vibration.
6) Record volts, amps and watts per phase in 30-minute increments.
7) Couple the motor. Perform a heat run per 46101-F electrical test
procedure. Load test must be a minimum of 4 hours.
8) Record vibration level in 30-minute increments throughout test
beginning at motor startup. When there are no proximity probes
provided record only the bracket vibration levels. For the last set of
vibration levels, record the vibration in 30-second increments for 10
minutes to record the frequency of the vibration modulation. Use the
recorded vibration data to review frequency sweeps from 0 - 250 Hz
for all points.
9) Record electrical data per 46101-F.
10) Perform a heat run test for a minimum of 4 hours. The loaded heat run
is level and ready for shutdown when there is no more than a 1°C
change in temperatures between two successive readings taken 30
minutes apart. Take a complete set of readings before shutdown.
11) Take hot resistance shutdown.
12) Note: Perform steps’ five (5) and six (6) only when the motor does not
meet the specified vibration levels at any specific location and
frequency under load and/or during the Cold Uncoupled.
13) Quickly uncouple the motor and cover 80% of the air inlet. The motor
must be running again within 20 minutes.
14) Run the motor uncoupled at rated voltage and speed. Record
vibration bearing temperatures immediately upon restarting the motor.
15) Note: If the loaded, hot or cold uncoupled vibration readings do not
meet the limits shown in Table 1 of the Appendix contact Mechanical
Engineering and perform the following calculations for each point that
fails.
16) Divide each hot uncoupled vibration point that exceeds the limits, by
the corresponding cold uncoupled vibration point to obtain the hot to
cold ratio.
17) Multiply this ratio, by the corresponding vibration point, with the highest
amplitude, recorded during the no-load mechanical run in Section D of
this procedure on the rigid mass.
18) Couple the motor back to the dynamometer. Perform speed-torque-
amp test per tests 46101-D and load performance at six (6) loads per
46101-E, when specified on the sales order. Hold for electrical
engineering to work up performance data.
19) On sleeve bearing motors perform a bearing inspection.

9. HEAT RUN
Reliance Specification: 46101-F
Industry Specification: IEEE 112-8
Location: Dynamometer
Purpose: Verify temperature rating
Procedure: 1) Load the motor by dynamometer to rated load torque/horsepower at
nameplate voltage and frequency.
2) Measure and record input volts, amps, watts, and temperatures of
RTDs and thermocouples every 30 minutes.
3) Repeat step 2 until the temperature has stabilized.
4) Once stabilization has been reached, power is removed from the
motor and consecutive stator winding resistance values are recorded.

10. LOCKED ROTOR SATURATION

Reliance Specification: 46101-C2
Industry Specification: IEEE 112-7.2
Location: Seismic Mass
Purpose: Verify locked rotor torque and current
Procedure: 1) Connect the torque arm to the motor shaft.
2) Set the voltage to 25% of rated voltage and apply rated frequency. If
the impressed torque and amp values are very high, the motor may be
tested with single-phase voltage.
3) Measure and record input volts, amps, watts, and torque.
4) Repeat steps 1 and 2 for higher voltages. Voltages will be limited such
that the impressed amps and torque do not exceed safe limits of the
test equipment and motor.

11. NO LOAD SATURATION

Reliance Specification: 46101-C1
Industry Specification: IEEE 112-5.3
Location: Seismic Mass/Dynamometer (Uncoupled)
Purpose: Determine the stator core loss and inherent running friction due to bearings
and fans.
Procedure: 1) Set the voltage to 125% of rated voltage and apply rated frequency.
2) Measure and record input volts, amps, and watts.
3) Repeat steps 1 and 2 for 6 other voltages ranging from 125% to 25%
rated voltage.

12. NOISE
Reliance Specification: 419530-14
Industry Specification: IEEE 85
Location: Aisle
Purpose: Verify sound level
Procedure: 1) Place assembled motor on rubber.
2) Record ambient noise at 4 positions around the motor. Each position
is located at a specified distance from the motor (typically 3 feet). The
average of all positions is recorded.
3) Energize motor at rated voltage.
4) Record sound level at 11 positions at a specified distance (typically 3
feet). Eight positions are around the motor and three positions are above
the motor. The average of all positions is recorded.

13. OVERSPEED UNBALANCED COASTDOWN

Reliance Specification: 419530-138 Part E
Industry Specification: API-541 / 547
Location: Seismic Mass
Purpose: Verify rotor dynamic performance with an unbalanced mass added. On
flexible rotors the location of the first lateral critical speed is confirmed
Procedure: 1) If the motor set-up has changed since the last test, prepare the motor
for testing per 419530-138 Part A.
2) The unbalanced weight per plane used for this test equals (4*(4W/N)),
where:
3) W = half the rotor weight in lbs.
4) N = the operating speed in rpm
5) Place the unbalance weight to each end of the rotor in phase. Perform
overspeed unbalanced coastdown test from 115% of operating speed.
Hold shaft on magnetic center and record the coast down to rest.
6) Place the unbalance weights 180° out of phase on the rotor. Perform
overspeed unbalanced coast down test from 115% of operating speed.
Hold shaft on magnetic center and record the coast down to rest.

14. PERFORMANCE (METHOD B)

Reliance Specification: 46101-E
Industry Specification: NEMA MG1-20.21, IEEE 112-3.4, 6.4
Location: Dynamometer
Purpose: Verify power factor and efficiency at different loads.
Procedure: 1) Load the motor by dynamometer to near rated temperature at
nameplate voltage and frequency.
2) Measure and record input volts, amps, watts, speed and hottest RTD
temperature reading at six approximate load levels from 150% rated
load down to 25% rated load. Being sure to include rated load (100%),
75% and 50%.
3) This data is used to determine power factor and efficiency at different
loads. Stray load loss is determined by linear regression.

15. PERFORMANCE (METHOD F)

Reliance Specification: 46101-AR
Industry Specification: IEEE 112-6.7
Location: Seismic Mass
Purpose: Verify performance of the motor.
Procedure: 1) Connect torque arm to motor shaft.
2) Set supply frequency to 60 hz and voltage such that current is
approximately 50% of full load amps.
3) Record volts, amps, kilowatts, winding temperature, and line
frequency.
4) Repeat steps 2 and 3 for 75%, 100%, and 115% of full load amps.
5) Repeat steps 2, 3, and 4 for 30 hz and 15 hz.
16. POLARIZATION INDEX
Reliance Specification: 412254-4
Industry Specification: IEEE 43
Location: Seismic mass
Purpose: Determine the condition and insulation resistance of the stator winding.
Procedure: 1) Bleed any residual charges on the windings by grounding.
2) Measure and record ambient temperature, winding temperature, and
humidity.
3) Apply specified test voltage between the winding and ground.
4) Record resistance every 15 seconds for the first minute and every 30
seconds for the second minute and every minute thereafter for 10
minutes.

17. ROUTINE MECHANICAL RUN TEST

Reliance Specification: 419530-138 Part D
Industry Specification: API-541 / 547
Location: Seismic Mass
Purpose: Verify vibration performance under no load conditions
Procedure: 1) Run the motor at rated voltage for 1 hour after the bearing
temperatures stabilize to a 1°C change per 30 minutes.
2) Record vibration level in 30-minute increments throughout test
beginning at motor startup. For the last set of vibration levels, record
the vibration in one (1) minute increments for 15 minutes to generate
time plots. When there are no proximity probes provided record only
the bracket vibration levels.
3) Review frequency sweep plots for all positions from 0 to 200 Hz.
4) Record bearing temperatures every 15 minutes throughout the test,
beginning at startup.
5) Record the following data every 30 minutes throughout the test
beginning at startup, stator temperatures, voltage, current and power
per phase.
6) Reduce voltage from rated voltage to ¼ voltage, hold shaft on
magnetic center and record vibration readings for all measurement
location.
7) Record the slow roll run-out during the coastdown at a speed between
300 and 200 rpm for each proximity probe position. Hold the shaft on
magnetic center.
18. ROUTINE TEST - STANDARD
Reliance Specification: 46101-B1 & 419530-19A
Industry Specification: NEMA MG1-20.16.2 & Part 7
Location: Seismic Mass
Purpose: Ensure that the unit is manufactured with the correct elements and meets
all the quality standards. In addition, sleeve bearing motors run twice, first
to assure proper bearing alignment and afterward to assure all other
aspects.
Procedure: 1) On sleeve bearing motors, measure and record air gaps at four
positions at both ends of the motor.
2) Measure and record winding resistance.
3) Measure resistance of electrical accessories.
4) Measure and record no load inputs (volts, amps, watts and speed).
5) Measure and record locked-rotor inputs (volts, amps and watts). Due
to equipment capacity limitations, locked rotor points may be taken at
a reduced voltage and/or single-phased.
6) Motor is rigidly bolted to the seismic mass for testing.
7) Motor is tested at rated voltage and speed at no load conditions for
thirty minutes.
8) After the motor has run for thirty minutes, vibration levels are recorded
for each bracket position on sleeve bearing motors the shaft vibration
levels are also measured. Bearing temperatures are recorded at this
time as well.
19. SETUP GUIDELINES FOR API-541 3RD EDITION TESTING
Reliance Specification: 419530-138 Part A
Industry Specification: API-541 / 547
Location: Seismic Mass and Load Stand
Purpose: Preparations for Testing Motor per API-541 3RD EDITION Requirements
Procedure: 1) When applicable, install bearing RTD's and when supplied, proximity
probes. Set the gap voltage on the proximity probes at 9 to 10 volts.
2) Connect stator RTD’s or thermocouples when performing routine
mechanical run and dynamometer tests.
3) Install a crowned half key and retaining collar on the shaft extension.
4) Mount the motor on the seismic mass for all no load testing and for
loaded testing mount the motor on the dynamometer. No testing on
isolation pads permitted.
5) Bolt the motor directly through the motor feet bolt holes - Do not clamp
the motor down to the mass. Have each motor foot torqued to 80 ft-lb.
Check foot deflection by loosening and then retightening each foot.
Torque the hold-down bolts one at a time to 80 ft-lb. each with a
torque-wrench to ensure repeatability. Foot deflection limited to no
more than 1.00 mil. Shim the motor feet to limit foot deflection to 1.00
mil or less, if necessary.
6) When a motor has provisions for flood lubrication, connect flood lube
system to the motor and operate the lubrication system as described
on the Dimension Sheet (D/S). Do not connect the flood lube system
for the bearing run.
7) When specified to record vibration levels, record (F/O, 1/2x, 1x, 1x
phase angles, 2x and for non- two poles record 60 Hz line frequency
and 120 Hz line frequency) vibration levels. Record shaft vibration
levels in mils and bracket vibration levels in in/sec. On sleeve bearing
motors, record the shaft vibration levels using proximity probes. Use
shaft sticks to measure shaft vibration levels when there are no
provisions for proximity probes.
8) List all the test equipment used for motor testing. Include equipment
description and the calibration date. Use the form on the 419530-143
for documentation.

20. SPEED TORQUE

Reliance Specification: 46101-D
Industry Specification: IEEE 112-7.3
Location: Dynamometer
Purpose: Verify the starting characteristics (torque and amps versus speed)
Procedure: 1) The power supply voltage will typically be set to a value lower than
rated (usually 50%).
2) Drive the motor to the desired speed.
3) Record volts, amps, speed, torque, and winding temperature.
4) Let the motor return to full speed to cool.
5) Repeat steps 2, 3, and 4 for a minimum of eight times.
21. STATOR CORE TEST
Reliance Specification: 419530-160
Industry Specification: API-541 / 547
Location: Rock Hill Service Center
Purpose: Verify the stator core interlaminar insulation integrity
Procedure: 1) Test shall be performed on the stator core prior to the insertion of the
stator coils.
2) Rated flux shall be maintained on the stator core for a minimum of 1/2
hour while continuously monitoring stator temperatures.
3) Deficiencies are defined as any core location which is 5°C above the
adjacent core temperature.

22. STATOR WINDING IMMERSION

Reliance Specification: 412254-1,3
Industry Specification: NEMA MG1-20.18.1
Location: Water Tank
Purpose: Verify the insulation system is sealed against moisture.
Procedure: 1) Megger the dry stator and record insulation resistance.
2) Immerse the core in a water solution containing a wetting agent.
3) Megger the wet stator for 10 minutes. Record initial insulation
resistance and at a period 1 minute and 10 minutes.
4) Hi-pot the immersed windings at 1.15 times rated voltage for 1 minute.
Record initial insulation resistance and at a period of 1 minute.
5) Remove stator from water.
6) Dry in oven.