Good Practice

Guide to
Maintain Motor Efficiency
Based on the 2019 and 2003 Rewind Studies
of premium efficiency, energy efficient,
and IE2 (formerlyEF1) motors
 Good Practice Guide to Maintain Motor Efficiency

Table of Contents
Introduction....................................................................................................................... 1
Terminology....................................................................................................................... 1
Energy losses in induction motors ................................................................................. 1
Core (iron) losses............................................................................................................ 2
Special issues for electrical steels................................................................................ 4
Stator I2R losses.............................................................................................................. 4
Rotor losses..................................................................................................................... 5
Friction and windage losses......................................................................................... 5
Stray losses..................................................................................................................... 7
Summary of factors that can increase motor losses................................................. 7
Motor repair processes ................................................................................................... 9
Preliminary inspection................................................................................................... 9
Motor nameplate(s) data......................................................................................... 9
Results of external inspection................................................................................. 11
Customer input......................................................................................................... 11
Dismantling the motor................................................................................................ 12
Terminal box layout and connections................................................................... 12
Orientation of end bracket and bearing caps.................................................... 13
Bearing sizes, types and clearances...................................................................... 13
Axial position of rotor relative to stator (drive end or opposite drive end)....... 13
Orientation of shaft with respect to the main terminal box................................ 13
Careful rotor removal to prevent damage to air gap surfaces or winding..... 13
Internal inspection................................................................................................... 13
Mechanical damage to components or signs of misuse .................................. 15
Motors with considerable contamination ............................................................ 15
Removing the old winding and cleaning the core................................................ 15
Recording the winding details................................................................................ 15
Core loss testing....................................................................................................... 15
Removing the old winding...................................................................................... 16
Cleaning the stator core......................................................................................... 18

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Good Practice Guide to Maintain Motor Efficiency

Table of Contents–continued
Rewinding the motor.................................................................................................. 19
Is the old winding the manufacturer’s original?................................................... 20
Copy (duplicate) rewinding................................................................................... 20
Changing to a two-layer lap winding................................................................... 22
Completing the winding......................................................................................... 25
Winding tests............................................................................................................. 25
Winding treatment................................................................................................... 26
Mechanical repairs that can affect motor efficiency............................................ 27
Repairs to cores........................................................................................................ 27
Shaft repairs.............................................................................................................. 27
Housing repairs......................................................................................................... 27
Bearings and seals................................................................................................... 27
Fans and fan covers................................................................................................ 27
Reassembling the motor............................................................................................ 27
Confirming the integrity of the repair....................................................................... 28
Bibliography.................................................................................................................... 29

EASA, Inc.
1331 Baur Blvd. • St. Louis, MO 63132 USA
+1 314 993 2220 • Fax: +1 314 993 1269
www.easa.com

Association of Electrical and Mechanical Trades (AEMT Ltd)

Co. Reg. No. 00397289 (England and Wales)
St. Saviours House • St. Saviours Place
York, YO1 7PJ • North Yorkshire • England, UK
+44 (0) 1904 674899 • Fax: +44 (0) 1904 674896
www.aemt.co.uk

Disclaimer
The information in this guide was carefully prepared and is believed to be correct, but neither EASA nor AEMT make any
warranties respecting it and disclaim any responsibility or liability of any kind for any loss or damage as a consequence of
anyone’s use of or reliance upon such information.

ii Copyright © 2021, EASA, Inc. (Version 0121)

 Good Practice Guide to Maintain Motor Efficiency

Introduction Anti-rotation device Rotor laminations

Anti-backlash assembly Rotor core
The purpose of this guide is to pro- Non-reverse ratchet
Backstop
Rain bonnet

vide repair/rewind practices and Drip cover

tips that will help service center Coupling

technicians and motor winders Bearing carrier

Bearing holder
maintain or increase the efficiency, Terminal box Bearing quill
Top hat
Outlet box
reliability and quality of the motors Conduit box Runner

they repair.
Junction box
Stand tube
Oil dam
Some of the included procedures Other key nomenclature items: Stand pipe
Thrust washer
derive directly from the 2019 and Spring washer
Stator laminations
Stacked stator
2003 rewind studies by EASA and
Pre-load washer
Core iron
Wave washer
AEMT of the impact of repair/re- Oil ring
Shaft
Coils
winding on motor efficiency. Others Oil slinger Windings

are based on the findings of an Sleeve bearing

Babbitt bearing
Rotor laminations
Rotor core
earlier AEMT study [1998] of small/ Plain bearing

medium size three-phase induction Bearing shell Rotor fan blades

Rotor fins
motors and well-established indus- Bold text indicates
try good practices .
Fill pipe
terminology used
Drain pipe
in this publication.
The procedures in this guide cover
all three-phase, random-wound in- Figure 1. Vertical AC motor nomenclature.
duction motors. Much of the guide
also applies to form-wound stators Energy losses in induction
of similar sizes.
(Note: This guide provides many specific pro-
motors
cedures and recommendations. Alternative There are five types of losses in an induction mo-
practices may accomplish the same results but tor (see Figure 3, Page 2):
must be verified.) ● Core losses in the stator and rotor
Terminology ● Stator I2R losses
The terms used to describe horizontal and ver- ● Rotor I2R losses
tical induction motors in this guide are those ● Friction and windage losses
commonly found in other EASA, AEMT, NEMA,
IEC, IEEE, and ANSI documents. These terms ● Stray load losses
are printed in bold type in Figure 1 and Figure 2 The core, friction and windage losses do not
(Page 2), with alternate terms listed beneath significantly change with motor load, provided
them. the motor is operated from a fixed voltage and

WARNING: HAZARDOUS AREA MOTORS

Some elements of this Good Practice Guide To Maintain Motor Efficiency, particularly those concerning
changes to windings, do not apply to hazardous area/explosion-proof motors (e.g., UL, CSA, IECEx).
Do not use this guide for those types of motors.

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 Good Practice Guide to Maintain Motor Efficiency

Figure 4 (Page 3) illus-

end turns
Coil extensions
Coils end ring Stator shroud
Belly band
trates how the losses vary in
eye bolt relation to load for a typical
Rabbet fit
Spigot fit
Lifting eye 4-pole induction motor.
axial thrust washer
air baffle
Shroud
external cooling fan
Core (iron) losses
Air deflector
bearing cap
Bearing retainer
Core losses can increase if ex-
Clearance fit Back cap cessive pressure is applied to
Flame path
Shaft opening Fan cover
the stator core (e.g., by fitting
Fan shroud a new stator frame with too
Keyway
Grease line
small a bore). Damaging the
Shaft Stator laminations interlaminar insulation (the
end bracket
Stacked stator
Core iron
very thin layer of insulation
End bell Core plate between each lamination
Punchings
Foot
Rotor skew
in the stator and rotor core)
Rotor laminations
Frame
Stator frame Rotor core can also increase core losses.
Drive end Opposite drive end
This can happen if the stator
is burned out at too high a
Figure 2. Horizontal AC motor nomenclature. temperature.

Table 1. COMPARISON OF LOSS

Friction and windage
Stray load (Wl) losses
(Wfw) losses DISTRIBUTION BY PERCENT FOR MOTORS
TESTED IN THE REWIND STUDIES
2003 2003 2019
2 pole 4 pole 4 pole Design factors
Losses average average average affecting losses
Core losses 19% 21% 22% Electrical steel, air
(Wc) gap, saturation, supply
Core (Wc) losses frequency, condition of
interlaminar insulation
Rotor I2R (Wr) losses Stator I2R (Ws) losses
Friction and 25% 10% 11% Fan efficiency and airflow
windage volume, lubrication,
Figure 3. Losses in the various parts of a motor. losses (Wf w) bearings, seals

Stator I2R 26% 34% 34% Conductor area, mean

frequency. The I2R and stray load losses increase losses (Ws) length of turn, heat
significantly as load is increased. dissipation
Both core and I2R losses (and particularly the Rotor I2R 19% 21% 19% Bar and end ring size and
rotor losses) may be higher when the motor is losses (Wr) material, amount of slip
supplied from a variable-frequency inverter.
Stray load 11% 14% 14% Manufacturing processes,
In many cases, losses can be decreased during the losses (Wl) slot design, air gap, con-
repair process by following good practice proce- dition of air gap surfaces
dures. and end laminations

Table 1 shows a breakdown of the averaged loss- Note: The single 2 pole motor in the 2019 study was not listed
es for the motors tested in the rewind studies. since it would not be a statistically valid sample quantity.

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 Good Practice Guide to Maintain Motor Efficiency

tions together, the next concern is to burn out the

windings at an appropriate temperature.
The interlaminar insulation may be an organic,
Total losses
chemical or oxide coating. Newer motors are
likely to have C-5 (inorganic) lamination insula-
Stray losses tion that can withstand higher temperatures than
that of older motors. Because winding insulation
Rotor materials degrade at lower temperatures than
kW losses

I2R
the interlaminar insulation, the burnout process–
properly done–will not harm the interlaminar
insulation.
The burnout oven should be fitted with a
chart-recorder to document that each motor is
Stator I2R Stator burned out at a safe temperature. The tempera-
I 2R
ture probe should be attached to the stator core
during the burnout process.

Core losses
Tight control of the burnout process is essential.
Burning out at a temperature significantly below
Friction and windage 680°F (360°C) may not entirely break down the
0 25 50 75 100 125 150 insulation on the old winding. In that case, it
Percent of full load will take more force to remove the coils and slot
insulation, which may damage to the core (e.g.,
Figure 4. Typical components of induction
splayed teeth) and increase the stray load losses.
motor loss plotted against load.
Burning out at more than 750°F (400°C), however,
increases the risk of damaging the interlaminar
The following factors affect the quality of the
insulation and may increase the core losses, espe-
laminations:
cially if the interlaminar insulation is organic or
● Core and tooth rigidity and ability to hold otherwise susceptible to high burnout tempera-
shape tures. Some other lamination insulation processes
● Damage caused by the failure (e.g., oxide steam-bluing, some waterborne and
some organic varnishes) require extreme caution
● Quality of the interlaminar insulation (core- and may not be suitable for burnout.
plate)
All satisfactory results in the rewind studies were
● Damage caused by burnout achieved with a burnout temperature of 700°F
● Damage caused by coil removal (370°C), with the temperature measured at the
tooth area of the stator core.
● Excessive grinding and filing
Loading cautions for burnout ovens. Do not
Burnout process. The stator core is composed stack stators in the oven; the temperature of the
of laminations–thin pieces of steel coated with stators on top may be increased by the burning
insulation to reduce eddy-currents in the core. stators underneath. Do not place stators in the
Assuming the failure did not blow a hole in the oven with the bores vertical; this is especially
core (thereby reducing its mass) or fuse lamina- critical with aluminum frames.

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 Good Practice Guide to Maintain Motor Efficiency

Core losses. Due to the wide variety of electri- It also is important to remember that:
cal magnetic steels in use, it is impossible to set ● Thin laminations with narrow or unsupported
rigid rules for core loss test acceptance. However, teeth are more susceptible to tooth distortion.
measuring core loss before burnout and after core
stripping and cleaning will identify significant ● Laminations with significant damage and hot
increases in core losses. If the core loss test losses spots may not be good candidates for rewind,
increase by more than 20%, consider replacing particularly when efficiency and reliability are
the motor. In special cases, consider restacking or major considerations.
replacing the laminations. For more information, see the earlier discussion
of the “Burnout process.”
Electrical steel considerations. The ability to
maintain motor efficiency or to minimize any Stator I2R losses
depreciation in efficiency is influenced by the
quality of the stacked stator core and its lamina- The stator I2R losses are often the largest com-
tions. ponent of loss. In motors of 45 hp (30 kW) and
The motor industry uses such a wide variety of above tested in the rewind studies, the average
electrical steels that it is difficult to generalize stator I2R losses were 31% of the total loss (range
their characteristics. The most common consider- 22 - 47%). Consequently, anything that affects
ations include: stator I2R losses can have a significant impact on
the efficiency of a repaired/rewound motor.
● Fully processed vs. semi-processed steel.
Stator I2R losses can be reduced by increasing the
● Carbon vs. silicon steel.
Table 2. EFFECT OF CHANGES
● Grain orientation–induction motors use
TO THE END TURN LENGTH
non-oriented electrical steel.
ON TYPICAL TEFC/IP54, 460V DESIGNS
● Hysteresis and eddy current losses ranging Full load Total Change in
from 1.5 to 6 watts/lb (3.3 to 13.2 watts/kg). End turn efficiency losses total losses
HP/kW Poles length (%) (watts) (%)
● Thickness ranging from 0.014” to 0.035” (0.4 to 10% short 93.1 2746 -2.8
0.9 mm). 50/37 4 Nominal 93.0 2825
● Interlaminar insulation materials ranging from 10% long 92.8 2911 3.0
C-0 to C-6. Most modern motors use C-5. 10% short 94.9 4020 -2.6
100/75 4 Nominal 94.8 4129
Special issues for electrical steels 10% long 94.6 4243 2.8
10% short 95.6 6921 -2.5
● Semi-processed steels are usually good candi-
200/150 4 Nominal 95.5 7099
dates for oven burnouts.
10% long 95.3 7278 2.5
● Safe burnout temperature depends on the inter- 10% short 92.7 2935 -2.9
laminar insulation. 50/37 2 Nominal 92.5 3024
Differences among world steel standards com- 10% long 92.3 3122 3.2
plicate this discussion, but the type of the 10% short 93.9 4881 -3.3
interlaminar insulation is the key issue. When in 100/75 2 Nominal 93.7 5047
doubt about the kind of interlamination insula- 10% long 93.5 5212 3.3
tion a motor has, the safest course is to contact 200/150 2 10% short 95.1 7697 -2.3
the motor manufacturer. Nominal 95.0 7875
10% long 94.9 8075 2.5

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 Good Practice Guide to Maintain Motor Efficiency

conductor cross-sectional area and/or decreasing

the mean length of turn (MLT). Changing the lS
winding configuration can increase the stator I2R le
losses, although some changes (e.g., increasing
the cross-sectional area) will reduce them.
Table 2 (Page 4) contains the results of an
earlier EASA study that show the impact on effi-
ciency of a 10% change in end turn length (about lS
a 5% change in MLT) for typical TEFC (IP54)
motors. Where it was feasible, reducing the MLT
improved the efficiency over the nominal value. d
From this it is clear that end turn length and MLT
are critical to motor efficiency.
Mean length of turn (MLT). Allowing the MLT
(Figure 5) to increase will increase stator I2R Diamond coil Round coil
losses and therefore decrease motor efficiency.
MLT = (2 x LS ) + (4 x Le) MLT = 2 (LS) + π d
Conversely, decreasing the MLT where possible
will reduce stator I2R losses to help maintain or Where: MLT = Mean length of turn
even improve efficiency. The goal is to reduce the L s = Straight section of coil
straight section of the coil where it exits the slot to L e = Coil extension
the minimum required to avoid mechanical strain
on the slot cell. Whatever coil shape is used, make Figure 5. Mean length of turn (MLT).
sure the coil end turns are no longer than those of
the original winding. machined during each of several repairs, sooner
Avoid reducing the MLT too much. Doing so or later the air gap will become a problem. The
could make the stator difficult or even impossible repair history of motors is rarely known, so most
to wind. It may even affect cooling, in extreme service centers are reluctant to machine the rotor
cases causing the winding temperature to rise. diameter.)

Rotor losses Friction and windage losses

Rotor losses should remain unchanged, unless The friction and windage losses can be increased
the rotor was damaged during the failure or its by:
diameter was changed by machining. Rotor loss- ● Badly fitted bearings, excessive interference
es will increase if the flux density is reduced as a fits.
result of a change to the stator winding or if rotor ● The addition or use of incorrect seals, lack of
cage (bars and end-rings) resistance is increased. seal lubrication, or damage to shaft surface (lip
They also can increase due to change/damage to seals) or end bracket surface (face seals).
rotor conductors of a squirrel cage motor.
● Installing an incorrect replacement fan.
Taking a skim cut of the rotor can also affect
rotor losses. Machining the rotor diameter (skim ● Over-greasing the bearings.
cutting) to increase the air gap can reduce losses Fans. External fans are another potential source
at the expense of power factor; however, too great of efficiency loss. Windage varies among fan
an increase in air gap will increase losses. Service designs, depending on factors like diameter, the
centers should avoid this procedure. (If a rotor is number and size of blades, material, and surface

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 Good Practice Guide to Maintain Motor Efficiency

finish. The most important variable, however, is When the application and environment call for
fan diameter. the reliability of sealed bearings, expect some in-
All else being equal, a fan with a smaller diameter crease in bearing temperature and friction losses.
moves considerably less air [(D2/D1) 5] than one A better alternative may be to install non-contact
with a larger diameter. That means it takes more seals or bearing isolators, which exclude contam-
energy to drive a fan having a larger diameter. inants without causing friction. Some bearing
As an example, it would take 28% more power manufacturers also offer non-contact sealed
to drive an otherwise identical replacement fan bearings.
whose diameter is 5% larger than the original.
That diverted power is lost power, which reduces 1000
motor efficiency.
It is good practice to use an identical replacement 800
for a damaged fan. Substituting a nonidentical
fan may change the efficiency of the motor. Of
600
course, if chemical processes or other consider-
ations make the original fan design impractical,
discuss alternatives with the motor manufacturer 400
to avoid adversely affecting efficiency.
It is also important to keep air passages clear–i.e., 200
the ducts and channels in the frame or core
through or over which cooling air passes. Wholly 0
or partially blocked ducts or channels may reduce 0 200 400 600 800 1000
friction and windage loss, but the reduced cool- Time (hours)
ing effect will increase other losses–particularly Figure 6. Over time, excess lubricant is forced
stator I2R loss–much more. This can lead to early out of the bearing, and friction losses are
failure as well as reduced operating efficiency. reduced. (Provided by Emerson Motor Co.)
Bearings. Bearings of C-3 internal clearance are
the standard for most electric motors. A bearing 1000
with a contact seal can create more friction than a
shielded, open or non-contact sealed bearing. The 800
Grease (full)
increased friction results in a slight drop in effi-
ciency. To avoid degrading efficiency, it is good
Input watts

600 Grease (half full)

policy to use the open bearing style installed by
the manufacturer. 400 Oil
Lubrication intervals, quantity and viscosity will
also impact the efficiency of an electric motor. 200
Follow the manufacturer’s guidelines for each
motor to maintain motor efficiency. The 2003 0
0 10 20 30
rewind study found that over greasing a bearing,
even by a small amount, increased the friction Time (hours)
losses by about 500 watts for some larger motors. Figure 7. Proper grease fill (half full) results in
Excess lubrication not only reduces efficiency; it a significant reduction in losses as the bearing
also causes local overheating, which can shorten “breaks in,” approaching the level of oil
bearing life dramatically. lubrication. (Provided by Emerson Motor Co.)

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 Good Practice Guide to Maintain Motor Efficiency

140 60
Stray losses
130
Stray load losses are typically 10 - 20% of total
motor loss. The high frequency harmonic fluxes
Full pack
Temperature ° F

50
120
that occur near the air gap surfaces of the stator
110 2/3 pack and the rotor core are a major source of stray loss.
1/3 pack 40 These are caused by magnetic interaction of the
100
Film pack stator and rotor teeth.
90
30 Stray loss can increase if the air gap surfaces of
80 the laminations are smeared together (e.g., by
0 1 2 3 4 5
Time (hours)
mechanical damage, excessive filing or grinding,
etc.). Stray loss will also increase if the air gap is
Figure 8. Short-term “break in” periods may not be
uneven (i.e., stator and rotor not concentric) or if
adequate to reduce bearing losses, regardless of fill,
the rotor core is axially displaced relative to the
as illustrated here. (From Lubrication Fundamentals,
1st ed. by Mobil Oil Corp.) stator (e.g., if the shaft is replaced and the rotor
core is incorrectly positioned).
Impact of too much bearing grease. Several Stray loss analysis. The stray load losses for
studies have found that over-greasing the bear- the motors in Group A of the 2003 rewind study
ings can increase friction losses (see Figure 6 and increased significantly. The cause was the me-
chanical damage done to the stator core (i.e.,
Figure 7 on Page 6 and Figure 8). For the 2003
splayed ends of lamination teeth) in removing
rewind study, grease was added to the bearings
the old windings and slot insulation. This in
of two rewound test units in Group A. No change
turn increased the pulsating or zigzag losses (see
in lubrication was made on the rest of the motors Figure 10, Page 8).
in the test. As expected, bearing friction on the
The burnout temperature for the motors in
over-greased motors increased and efficiency
Group A was 660°F (350°C), which is too low to
dropped 0.3 to 0.5%. Figure 9 illustrates the de-
completely break down the old winding insu-
crease in losses over time for one of the 60 hp (45 lation. As a result, it took excessive force and
kW) motors in the 2003 rewind study. extra cleaning to strip out the old windings. The
resultant mechanical damage increased stray load
1000 losses.
The burnout temperature for motors in Groups B,
900 C and D of the 2003 rewind study was increased
WF loss (w)

to 680 - 700°F (360 - 370°C). This broke down the

old insulation more completely, making it easier
800 to remove the windings and clean the slots. Since
lamination teeth were not damaged in the pro-
700 cess, the stray load losses did not increase.
0 2 4 6 8 10
Time (hours) Summary of factors that can
Figure 9. Reduction in F & W losses during the increase motor losses
break-in run for a 60 hp (45 kW) motor with
Listed below are factors that can affect the differ-
proper grease fill tested in the 2003 rewind study.
ent energy loss components in induction motors.

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 Good Practice Guide to Maintain Motor Efficiency

● Mechanical damage to core (e.g., splayed lami-

FRaMe a nation teeth, smeared laminations)

a Stator I2R losses

● Increased MLT of coils (end turns that are too
STaTOR long)
● Reduced stator conductor total cross-sectional
area
● Some changes to the stator winding
C configuration
Rotor losses
● Change to end ring cross section
STaTOR ● Change/damage to rotor
laMINaTION b
● Machining the rotor
● Flux density change (e.g., due to stator winding
IRON change or replacing magnetic steel shaft with
non-magnetic material)
e Friction and windage losses
● Changes to bearings
F
G ● Changes to seals
MIN MaX
● Changes in lubrication
INTeRMeDIaTe ● Changes to fan(s)
● Changes to air passages
baR
laMINaTIONS

H ● Changes in operating temperature

Stray loss
eND RING ● Damage to air gap surfaces
Figure 10. Components of stray loss. ● Uneven air gap (i.e., rotor eccentric with re-
spect to stator bore)
Stator core losses ● Change in air gap
● Flux density change ● Damage to end laminations
● Excessive radial or axial pressure on core
● Excessive heating during burnout (i.e., damage
to interlaminar insulation)
● Type of coreplate used (some coreplates cannot
withstand normal burnout temperature–e.g.,
steam blued)

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 Good Practice Guide to Maintain Motor Efficiency

Motor repair processes 1.0 Preliminary inspection

Most repair processes, if done improperly, can The preliminary inspection forms an important
reduce motor efficiency. Conversely, doing them part of the complete motor repair record and
well will maintain and may even improve effi- may yield vital clues about the cause of failure.
ciency. It is also important to keep clear, concise It is important to include all data sources on a
written records throughout the repair process. data card like the ones shown in Figure 11 and
Figure 12 (Page 10). In particular, record the
Key points following information:
The main motor repair processes include:
Key points
● Preliminary inspection
● Motor nameplate(s) data
● Dismantling the motor
● Results of external inspection
● Documenting and removing the old winding
and cleaning the core ● Customer input
● Rewinding the motor 1.1 Motor nameplate(s) data
● Mechanical repairs ● Record all the data on the nameplate (see
● Reassembling the motor Figure 13 and Figure 14 on Page 11). Some
The following sections provide good practice pro- codes, numbers or letters which seem meaning-
cedures for each stage of the repair process. less may be very important if it is necessary to

HP/kW RPM Poles Manufacturer

SLOTS TYPE VOLTS
COILS MODEL AMPS
GROUPING STYLE PHASE
TURNS/COIL AUX.DEVICE EFF. HERTZ
WIRE SIZE LEAD LENGTH # LDS FRAME
WIRES IN MULTIPLE DEG C RISE DUTY DEG C AMB
PITCH: 1 TO SERIAL # INS CLASS
CONNECTION ENC TYPE SVC FCTR
JUMPER COIL DENSITIES: CMA
CORE LENGTH A/MM2
CORE ID AGD
BACKIRON THD
SLOT DEPTH BID
TOOTH WIDTH
LBS WIRE
JOB NUMBER
CUSTOMER

Figure 11. Original polyphase AC winding data sheet.

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Good Practice Guide to Maintain Motor Efficiency

AC Winding Particulars

Customer:
Maker:
Serial No: Model: Enc:

HP/kW V A RPM

Stator Rotor PRE-VARNISH TESTS

Section Existing New Checked by
Core Length WINDING RESISTANCE TO EARTH
Core Diameter
No. Slots
No. Coils RESISTANCE PER PHASE
Turns/Coil
Sections/Coil
Size of Conductor PRESSURE TEST TO EARTH
No. Cond. in //
Slot Depth
Tooth Width PRESSURE BETWEEN PHASES
Back Iron Length
Coil Pitch
Weight of Coil STATIC TEST Y/Δ
Winding Type TEST VOLTAGE
Slots/Pole/Phase
Coil Groups amps amps amps
No. // Circuits POLARITY CHECK
Connections
CE Projection
NCE Projection OTHER TESTS
Insulation Class
Lead Section
DIAGRAMS OR OTHER DETAILS

DATA TAKEN BY:

WINDINGS COMPLETED BY:

CHECKED AND PASSED BY:

DATE:

Figure 12. Original polyphase AC winding data sheet.

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 Good Practice Guide to Maintain Motor Efficiency

1.2 Results of external inspection

CATALOG # MODEL #
Look for and record:
SHAFT END BRG OPP END BRG ● General condition–old/new, dirty/clean, etc.
FR TYPE ENCL
PH MAX AMB °C ID#
● Cooling air ducts clear/obstructed–may have
INSUL CLASS DUTY WT BAL caused overheating (see Figure 15).
HP RPM SF HZ
● Shaft discolored (brown/blue)–sign of rotor
VOLTS
AMPS
MAX KVAR
CODE
NEMA NOM EFF
DES
overheating or bearing seizure.
SF AMPS PF GUARANTEED EFF ● Parts missing, damaged or previously re-
placed/repaired–e.g., seals, stator cooling ribs,
fan, fan cover, terminal box, etc.
1.3 Customer input
Customers may be able to provide:
Figure 13. NEMA motor nameplate
with efficiency rating. ● Operating environment–temperature, vibra-
tion, etc.
● Type of driven equipment.
● How many hours/day motor runs.
aC MOTOR IeC 60034 Ie3
● Approximate motor load.
TYP SER. NO. YEAR
KW r/min V A HZ
● How often it is started.
KW r/min V A HZ ● The type of starter used.
DUTY INSUL AMB °C RISE K DESIGN 3 PHASE
COS Ø CODE IP IC SERVICE FACTOR ● Whether the motor has been rewound before.
GREASE DE BRG NDE BRG ● How long the motor has operated since new (or
DIAG IA/IN MA/MN kg MOTOR WT
since last rewind).
● Unusual events–e.g., power outage, lightning

Figure 14. IEC motor nameplate

with IE3 efficiency rating.

contact the manufacturer for parts or informa-

tion. Taking a digital photo of the nameplate
helps assure that all data on it is accurately
recorded.
● Remember that there may be more than one
nameplate. Some OEMs fit their own name-
plates (which sometimes replace those installed
by the motor manufacturer), and some repair-
ers add a plate indicating the motor has been
repaired previously.
● Check whether the motor is energy efficient
Figure 15. Motor with blocked cooling fins.
(IE2) or premium efficiency (IE3)

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 Good Practice Guide to Maintain Motor Efficiency

strike, water damage, problem with driven diately adjacent to terminals does not show any
equipment, etc. signs of overheating (discoloration or brittle-
● Power supply and starting ness). If it does, replace the leads. Overheating
▪ Across line/direct on line may have been caused by a poor connection.
▪ Soft start
● Confirm that all terminals are firmly crimped
▪ Part winding start
or brazed to winding leads.
▪ Inverter
▪ Wye-delta/star-delta ● Record size and type of lead wire.
● Record lug size and style.
2.0 Dismantling the motor
Sometimes it is obvious from its outward appear-
ance that the motor is not repairable and that a
new one must be supplied. More often, however,
the motor must be dismantled before this deci-
sion can be made. It is essential to dismantle the
motor carefully and to keep adequate records to
ensure that if the motor is repaired it can be reas-
sembled correctly. Place all parts that are not to
be repaired in a suitable bin or tray that is labeled
with the motor serial number or job card number.
Key points
● Terminal box position, layout and connections As received
● Orientation of end brackets and bearing caps
● Bearing sizes, types and clearances
● Axial position of rotor relative to stator (drive
end or opposite drive end)
● Orientation of shaft with respect to the main
terminal box
● Careful rotor removal to prevent damage to air
gap surfaces or winding
● Internal inspection
● Mechanical damage to components or signs of
misuse
● Motors with contamination
As shipped
2.1 Terminal box layout and connections
● Record markings on both winding leads and Figure 16. This motor was reassembled with
terminals. the shaft extension on the wrong end. Punch
marks on the stator frame and end bracket
● Record positions of any links between termi- define orientation, preventing this problem
nals (make sketch). with blocked cooling fins.
● Check that insulation on winding leads imme-

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 Good Practice Guide to Maintain Motor Efficiency

2.2 Orientation of end bracket and bearing

caps
End brackets and bearing caps should be in-
stalled in exactly the same positions as originally
fitted. Orientation of the grease ports should
place the inlet at or near the top of the bracket to
assure proper relubrication. Therefore, indelibly
mark all end brackets and stator frames at both
ends of the motor (e.g., by punch-marking the
components with a center punch) before disman-
tling the motor (see Figure 16, Page 12).
2.3 Bearing sizes, types and clearances
Most motors have a ball bearing at each end. Figure 17. Rotor removal using a rotor
Some may have a roller bearing at the drive end removal tool.
to increase the radial load capacity, or thrust
bearing(s) for high axial loads. Always fit new
bearings of the same type as those removed, un- 2.6 Careful rotor removal to prevent
less they were misapplied. damage to air gap surfaces or winding
The following items are critically import in bear- The rotor presents a considerable overhung load
ing selection: when one end bracket has been removed. Al-
lowing it to scrape along the stator bore during
● Bearing enclosure
rotor removal can damage the air gap surfaces of
● Fit and tolerance both stator and rotor and increase losses. Wind-
● Precision class ing damage can also result. An effective way to
● Internal clearance remove and replace rotors in horizontal motors is
● Load application by using a rotor removal tool (see Figure 17).
● Type of lubricant 2.7 Internal inspection
2.4 Axial position of rotor relative to stator Look for and record:
(drive end or opposite drive end) ● Water or dirt ingress
The rotor should be centered axially within the ● Condition of stator and rotor cores–damage or
stator core. If it is displaced axially, centering overheating
forces will exert pressure on the bearings. If it is ● Condition of winding–discoloration, type of
displaced beyond the end of the stator core, mag- failure
netizing current will increase. Note position of
axial thrust washer when dismantling the motor 2.7.1 Water or dirt ingress
(i.e., DE or ODE). Loose dust, water marks or rust on internal
2.5 Orientation of shaft with respect to the surfaces, particularly in the bottom of the motor,
main terminal box may have been caused by water or dirt ingress,
which can contribute to failure. However, on
Document the mounting position of the shaft in totally enclosed (TE) or totally enclosed fan
relation to the leads (e.g., NEMA F1 or F2, IEC cooled (TEFC) machines, water marks or rust can
IM B3). There are many ways to do this. Some be caused by condensation of the air inside the
repairers describe this as “leads left facing shaft” machine as it cools down.
or “shaft right facing leads.”

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 Good Practice Guide to Maintain Motor Efficiency

2.7.2 Condition of stator and rotor cores–

damage or overheating
The stator and rotor cores may have been
damaged in a number of ways, including the
following:
● Core rub, often due to failure of one of the
motor bearings or rotor pullover caused by
excessive radial load. This smears the air gap
surfaces of the laminations together and can
increase eddy current loss. Depending upon
the extent of the damage, the motor may not be
repairable.
● Major mechanical damage to either the stator
or rotor core. Pieces missing or fused together
may sometimes be caused by a major electrical
fault, such as a short circuit inside the slots. Figure 19. Overall discoloration of the stator
Any application with an ungrounded system winding–usually indicates excessive temperature.
or poor ground fault protection is particularly Check load, power supply and cooling.
prone to this type of damage. If such damage
has occurred, weigh its effect on motor efficien- Note: Eddy current losses follow a square law
cy and performance when considering a repair with respect to heating–i.e., if the eddy current
(see Figure 18). doubles, the heating effect increases four times.
Serious overheating of the stator or rotor Therefore, a small increase in eddy current loss
cores. If the interlaminar insulation is damaged, can have a large effect on motor temperature
eddy currents will increase, causing excessive and efficiency. Serious overheating of the core
iron losses (see Figure 19). is sometimes evident from discolored wedges,
topsticks or air gap surfaces that may range from
light straw to various shades of blue, depending
upon the temperature reached.
2.7.3 Condition of winding–discoloration,
type of failure
Overheating of the winding does not normally
constitute irreparable damage, but the repairer
should carefully inspect the windings and try to
determine the cause of failure.
A winding that is evenly discolored at both ends
may indicate a failure due a ventilation problem,
overload or low voltage. Check the load condi-
tions with the customer; a motor with greater
power may be needed for the application. In that
Figure 18. Major mechanical damage to the case, rewinding the old motor may result in an-
stator bore; not repairable unless the core is other failure due to overload, possibly within the
restacked or replaced. warranty period offered by the repairer.

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 Good Practice Guide to Maintain Motor Efficiency

Most winding failures have many possible caus- testing is carried out at fixed points throughout
es, and diagnosing these is beyond the scope of the process.
this guide. For more information, consult EASA’s
book Root Cause Failure Analysis. Excellent photo- 3.1 Recording the winding details
graphs of different types of winding failure also It is important to record the full details of
are available in the EASA brochure “Failures in the old winding accurately and permanently
Three-Phase Stator Windings.” (see Figure 11 on Page 9 and Figure 12 on
Page 10). It is a good idea to collate all the
2.8 Mechanical damage to components or
winding data gathered over time into a winding
signs of misuse
data bank. The data to record are listed in the key
Mechanical damage may affect motor perfor- points; the following explanatory notes may also
mance. Look for: be helpful.
● Damage to the fan or fan cover Document the appropriate fields to ensure that
● Damaged or blocked cooling ducts/channels/ the winder can duplicate the winding, and the
ribs engineer can confirm its suitability.
● Fans or air baffles incorrectly located or missing Note: If the motor has been rewound previously,
● Shaft discoloration adjacent to either bearing the winding may not be the original and may
(overload or misalignment) not be the correct one for the motor. Try to verify
observed data from another source (e.g., your
2.9 Motors with considerable own data bank, the EASA database or the manu-
contamination facturer).
If the exterior is packed full of contaminants, Key points–recording the winding details
address maintenance procedures or consider a
different enclosure. If the winding is packed full ● Winding configuration (lap, concentric, single,
of contaminants, the enclosure may not be suit- two or three layers, etc.)
able for the operating environment. ● Number of slots

3.0 Removing the old winding and ● Number of poles

cleaning the core ● Number of phases
There are four elements to this task: ● Number, size and marking of leads
● Recording the winding details on appropriate ● Turns/coil
data cards or sheets (see Figure 11, Page 9,
● Grouping
and Figure 12, Page 10)
● Coil pitch(es)
● Core loss testing
● Removing the old winding ● Connections

● Cleaning the stator core in preparation for ● Coil extension/overhang–connection end

rewinding ● Coil extension–non-connection end
Although removal of the old winding and ● Number and size of wires in each coil
cleaning the core are necessarily carried out
sequentially, recording the winding details is a 3.2 Core loss testing
coordinated activity carried out both before and The best safeguard against burnout-related prob-
during winding removal. Likewise, core loss lems is to perform a core loss test before burnout

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 Good Practice Guide to Maintain Motor Efficiency

and after the core has been stripped and cleaned. Table 3. LEVELS (IMPACT) OF CHANGES
Commercial core loss test equipment can simplify IN CORE LOSSES
the process, or a loop test (also called a “ring flux
Levels Change in core loss, %
test”) can be performed using the procedure in
the EASA Technical Manual. None to slight Not measurable

Commercial core loss testers can give an indica- Threshold of measurement 20% increase
tion of whether or not the stator core losses have Moderate 40% increase
been affected by the winding removal process.
Consequential 60% increase
They normally will not record the same core loss
as would be measured during a load test on the Significant 80% increase
same machine. One reason for this is that the Major 100% increase
distribution of the flux induced by the tester in
Excessive >100% increase
the core is not the same as that induced by the
machine’s winding, particularly when the rotor is Catastrophic >200%
removed. Inaccuracies tend to worsen approach-
Reference: CSA C392:20, Table A.1.
ing the operating limits of the tester, so always
use testers well within the manufacturer’s recom-
during coil removal [e.g., teeth splayed (flared),
mended operating range.
end laminations buckled from excessive force
Core loss testers can be useful provided that the or heat, etc.], the core losses and stray losses
same tester at the same setting is always used for will increase. To avoid this, burn out the core at
each test on a given core. sufficient temperature to break down the wind-
Key points–core loss testing ing insulation fully, so the coils can be removed
without undue force.
● Conduct all tests using the same core tester.
● Make sure the tests are conducted within the 3.3.1 Step 1–Cut off one coil extension
manufacturer’s recommended operating range (usually the opposite connection end)
for the tester being used. Cut off the coil extension of the winding as close
● Carry out tests: to the stator core as possible without damaging
▪ Before burnout the stator core. Cutoff machines are available
▪ After the core has been cleaned prior to re- commercially for this purpose (see Figure 20,
winding. Page 17). Regardless of the method used to cut
off the coil extension, be careful not to damage
● Remember that figures obtained are compara-
the laminations.
tive, not actual losses.
● If the core loss increases by more than 20% (see 3.3.2 Step 2–Remove the old stator winding
Table 3): If removing the windings requires excessive force
▪ Make sure the settings of the core loss tester or damages the laminations, the burnout process
have not been changed and repeat the test. was not done at a suitable temperature or time
▪ If the repeat test confirms the increased loss, duration. The best step at this point is to repeat
repair the core or consider replacing it. the burnout cycle.
3.3 Removing the old winding 3.3.3 Core damage caused by overheating
The stripping process can directly affect motor The coils must be heated sufficiently to burn out
efficiency. If the stator laminations are damaged the old insulation from the windings without

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 Good Practice Guide to Maintain Motor Efficiency

All satisfactory results in the rewind studies were

achieved with a burnout temperature of 700°F
(370°C).
3.3.4 Burnout using a controlled
temperature burnout oven
The varnish and the insulation must be broken
down before the windings can be removed from
the stator core. This is commonly done with a
controlled temperature burnout oven.
A distinct advantage of this method is that it
provides a tightly controlled burnout process.
Properly done, it ensures that the stator core will
not reach a temperature that could damage the
interlaminar insulation. It is important to set the
oven temperature to monitor the temperature of
the stator core, and to follow the oven manufac-
turer’s instructions regarding cleaning and safety
(see Figure 21).

Figure 20. Winding cut off machine.

damaging the interlaminar insulation of the stator

core. The temperature required depends on the
type of insulating varnish used, with epoxy resins
usually requiring the highest temperature.
The stator core is made of thin steel laminations
that are insulated from one another by an oxide
coating or an organic or inorganic varnish. This
interlaminar insulation can be damaged if the
stator core gets too hot, resulting in increased iron
losses and reduced motor efficiency. Figure 21. Controlled temperature burnout oven.

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 Good Practice Guide to Maintain Motor Efficiency

Loading cautions for burnout ovens: Do not ● Caution: Some motors may have the connec-
stack stators in the oven; the temperature of the tion brought out on both coil extensions.
stators on top may be increased by the burning
3.4 Cleaning the stator core
stators underneath. Do not place stators in the
oven with the bores vertical because the cores After the old winding has been removed from the
may shift; this is especially critical with alumi- core, slot insulation and other debris may remain
num frames. in the slots. This must be removed carefully to
avoid damaging the core. If the teeth of the lam-
3.3.5 Removing the old winding inations at the end of the core have been pulled
When the heating process is complete and the sta- outwards (splayed) during coil removal, reposi-
tor temperature is safe to work with, pull out the tion them with minimum force.
old winding, taking care not to damage the core
(e.g., by splaying the end teeth outwards). 3.4.1 Core preparation
When removing the coils, pull them away from Keep filing and grinding to the minimum re-
the bore at a slight angle to keep the conductors quired to correct damaged areas. Removal or
from snagging or bending the end laminations. If shorting of laminations will increase core losses.
a coil is difficult to remove, reduce the possibility Unless corrected, severe core damage due to mo-
of damage by applying uniform pressure to the tor failure (e.g., rotor rub resulting from a failed
teeth spanning it. (Remember, splayed teeth will bearing) will decrease motor efficiency. Carefully
increase stray losses.) weigh this against the customer’s need to return
the motor to service. In some cases, repair may be
Burning out a core at too low a temperature often a stopgap measure until a replacement motor can
increases stray losses due to the physical damage be obtained.
inflicted on the core when the coils are removed.
Burning out the stator at sufficient temperatures 3.4.2 Methods of removing slot insulation
will prevent this problem. In addition, safe burn- Of the various ways to remove insulation from
out temperatures will not increase eddy current the slots following burnout, these methods
losses because they will not damage interlaminar proved to be satisfactory in the rewind studies:
insulation.
● Careful scraping using a sharp knife to sepa-
Note: If removing the windings requires ex- rate the remaining pieces of slot liner material
cessive force or damages the laminations, the from the core.
burnout process was not done at a suitable tem-
perature. The best step at this point is to repeat ● High-pressure washing using a commercial/
the burnout cycle. domestic high-pressure washer after which
the core must be baked dry (see Figure 22,
Key points–removing the old windings Page 19).
● Cut off one coil extension using a winding ● Abrasive blasting using mildly abrasive ma-
cutoff machine. terial such as walnut hulls, crushed corncobs or
● Burn out old insulation at appropriate tempera- plastic beads. Blasting with more abrasive ma-
ture in a controlled-temperature burnout oven terials like sand, crushed flint, ceramic pellets
set to monitor core temperature. or even glass beads may cause surface shorting
● Do not overheat the core. of the laminations, which increases core and
stray losses.
● Remove the winding without damaging the
core. ● Wire brushing using a medium/soft wire
brush.

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 Good Practice Guide to Maintain Motor Efficiency

nations in the damaged area and treat them with

insulating material (coreplate) of an appropriate
temperature rating. Insulating varnish may also
seep between the separated laminations when the
new winding is impregnated, helping to restore
the interlaminar insulation.
If the damaged area of the core is excessive, there
is a risk that losses will have been increased
significantly and that motor efficiency will be
reduced. The best solution in such cases is to
replace the core, or to dismantle, reinsulate and
rebuild it.
Key points–cleaning the stator core
Figure 22. This core has been partially
Satisfactory methods for cleaning stator slots
cleaned by using a high-pressure washer to
remove the slot insulation debris.
include:
● Careful scraping with a sharp knife.
Avoid using files or grinders to remove slot insu- ● High-pressure washing.
lation. These can smear the laminations together
and increase eddy current losses near the air gap ● Blasting with a mildly abrasive material.
surfaces of the core. ● Brushing with medium/soft wire brush.
3.4.3 Damaged teeth at the end of the After cleaning the slots:
core ● Reposition damaged teeth
Sometimes teeth on the end laminations are ● Repair minor damage to air gap surfaces
splayed when the coils are removed. It is import-
ant not to hammer them excessively to get them ● Replace or reinsulate and rebuild cores if major
back into position. The use of a soft-faced ham- damage has occurred.
mer with minimum force is recommended.
4.0 Rewinding the motor
3.4.4 Damage to air gap surfaces of core In choosing a replacement winding the repairer
The air gap surfaces of the stator and/or rotor has two options:
cores may have been damaged. The most com- ● Copy (duplicate) the winding already in the
mon damage results in the laminations being
motor (provided it has the manufacturer’s
smeared together. In the case of rotor drag, using
original data).
a bore sander to scrub the affected area before
burnout is advisable. ● Choose a different style of winding that will
perform as well as or better than the original.
If the damaged area is not extensive, the effect on
losses or efficiency should not be significant. In Most repairers can redesign motors to make them
cases of relatively minor damage, bumping the more energy efficient. Most of the time, however,
affected area axially will usually improve things. the best way to maintain motor efficiency is to
(This is sometimes called “watt-knocking, since duplicate the original winding, while increasing
it “knocks” the watts out of the core.) If this does the copper cross sectional area as much as possi-
not work, use a sharp knife to separate the lami- ble and keeping the end turns as short as possible

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 Good Practice Guide to Maintain Motor Efficiency

(certainly no longer than those of the original

winding). Note, though, that in some designs, the
coil extension is critical for heat dissipation. If it
is too short, the temperature of the winding may
rise, causing I2R losses to increase.
When production volume justifies the cost, motor
manufacturers use automatic coil winding and
inserting machinery to produce motors with
concentric coil groups (see Figure 23). Repairers
often find lap windings much quicker and easier
to install (see Figure 24). This section therefore
sets out the basic rules (in terms of maintaining
efficiency) for just two types of rewind:
● A “copy” (or duplicate) rewind
● Changing the original concentric winding to a
conventional lap winding
Figure 23. Typical concentric winding.
4.1 Is the old winding the manufacturer’s
original?
Experienced technicians often can tell by looking
at a winding that it was wound by the manu-
facturer. Even so, it usually is best to check the
winding data using EASA’s Motor Rewind Data-
base software. If the repairer has a winding data
bank, this may provide useful information as
well.
There are other clues, however. Repairers often
are more careful about layering wires neatly in
coils than are manufacturers. They also tend to
use larger lead wire sizes and more substantial
phase insulation and bracing.
These differences are not a criticism of manu-
facturers’ windings. They merely reflect the fact
that manufacturers’ winding processes are often Figure 24. Typical lap winding.
wholly or partially automated, whereas almost all
repair work is done by hand. Most service centers it is the manufacturer’s original winding data, the
also try to prevent future failures of the motors core can now be prepared for rewinding. Even
they rewind by upgrading the coil bracing, insu- though the coil pitch (or pitches), turns/coil and
lation systems, etc. the connections will be the same as those of the
4.2 Copy (duplicate) rewinding original winding, two changes could be made
that will help to maintain or even slightly im-
If the details of the old winding have been record- prove the efficiency of the rewound motor:
ed (see Section 3.1, Page 15), and provided that
● Minimize the length of the coil extensions.

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 Good Practice Guide to Maintain Motor Efficiency

● Increase the copper cross-sectional area per

turn.

4.2.1 Mean length of turn (MLT)

It is important that the mean length of turn (MLT)
of the new winding is not greater (preferably less)
than that of the old winding. Otherwise, the new
winding will have higher resistance than the orig-
inal and therefore higher I2R losses (see Figure 5,
Page 5). When energy efficiency is the primary
consideration, do not convert from concentric
to lap without first calculating the MLT for both
windings and confirming that the total winding Figure 25. Typical coil extension
resistance will be lower. for a 4-pole motor.
The distance around the coil also changes with
the span. A wider span requires a longer conduc- to the following rules will prevent this:
tor–the additional length times the turns per coil. ● Keep the coil extensions (see Figure 25) with-
A longer conductor has greater resistance, so the in the measured dimensions of the original
total winding resistance partly depends on the winding.
coil span(s) selected.
● Do not extend the slot cell beyond the slot ends
The coil extension–the distance the winding any more than is necessary to prevent strain on
protrudes past the core on each end–also affects the slot cell.
the conductor length. The MLT can be controlled ● Do not extend the straight portions of the coil
by careful fitting when the coils are made. The sides any farther than is necessary to clear the
shorter this length, the lower the total winding slot insulation.
resistance, which in turn increases the efficiency.
With careful fitting, a diamond coil requires a Reducing the length of the coil extension will
shorter MLT than a round nose coil. While the reduce the amount of copper in the winding and
difference in length is slight (about 3 - 7% less reduce losses. If taken too far, however, this prin-
length in the end turn area), any decrease in resis- ciple can make winding a stator difficult or even
tance is beneficial. impossible. Cooling may even be affected–in
extreme cases causing the motor to run hotter.
4.2.2 Minimize the length of the coil By careful specification of the winding and coil
extensions dimensions, it is nearly always possible to equal
The coil extensions consist of “inactive” copper or reduce the copper losses of the manufacturer’s
that merely connect the “active” conductors or original winding. Record the coil dimensions of
coil-sides inside the slots. For most stator wind- the new winding.
ings (especially in 2-pole and 4-pole motors) the
copper in the coil extensions weighs more than 4.2.3 Winding resistance and heat
the copper in the slots and contributes substan- dissipation
tially to the total stator I2R losses. It is therefore Likewise, careful fitting usually can produce a
important to keep the coil extensions as short as winding with lower resistance than the original.
possible. If the MLT of the rewind exceeds that of Lower resistance reduces the I2R losses, making
the original, the I2R losses will increase. Attention the motor more efficient. All else being equal, a

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 Good Practice Guide to Maintain Motor Efficiency

carefully fitted rewound motor can be of higher 4.2.4 Increase the copper cross-sectional
efficiency than the original. As a general practice, area in each coil
the service center should replace the stator wind- It often is possible to increase the copper
ing with an exact duplicate of the one it removed. cross-sectional area in each coil when hand-wind-
That means the same wire size, winding type, ing motors that were originally machine wound,
turns, span and coil extension. or when rewinding an older motor. The draw-
Be careful to not increase the coil length to make backs are that it takes more copper and can add
the windings easier to install. That will increase significantly to winding times if overdone. It
total winding resistance. Increasing the coil exten- also is harder (and may even be impractical)
sion also will increase total winding resistance. to do with energy efficient (IE2) and premium
As mentioned earlier, when energy efficiency is efficiency (IE3) motors. Where practical, though,
the primary consideration, do not convert from increasing the copper cross-sectional area of each
concentric to lap without first calculating the coil helps reduce I2R losses and maintain (or im-
MLT for both windings and proving that the total prove) motor efficiency after a repair.
winding resistance will be lower. Experience will tell how much the copper area
When comparing lap and concentric windings, can be increased. The best method is to change
conductor sizes in each coil, remembering that
also consider the exposure of each coil to the air
the slot fill (i.e., the cross section of copper in
stream that cools the windings. Each coil of a lap
each slot/slot area) increases if fewer, larger
winding has the same exposure to airflow, unlike
conductors are used, but so does the difficulty
the layers of a concentric winding that vary in
of inserting the winding. Be sure to record the
their ability to dissipate heat. Avoid “buried
conductor sizes used in new winding.
coils” (see Figure 26), which tend to shorten insu-
lation life and sometimes prevent good varnish Key points–copy rewinding
impregnation. These drawbacks can apply to the
● Check that the old winding has manufacturer’s
middle layer of a 3-tier concentric winding. When
original data, if available.
copy-winding a 3-tier concentric winding, insert-
ing the coils in the same manner as a lap winding ● Use the same winding configuration.
balances the cooling effectiveness. ● Keep the coil extensions as short as practical.
● Keep the length of the coil extension the same
(preferably less).
● Use the same coil pitch (or pitches).
● Use the same turns/coil.
● Use the same (preferably larger) copper
cross-sectional area per turn.
● Use the same or shorter MLT.
Doing the above should maintain or reduce the
(temperature corrected) winding resistance.
4.3 Changing to a two-layer lap winding
Assuming no stator or rotor damage, and no
reduction in the circular mils/amp, the potential
efficiency of the motor should remain unchanged
Figure 26. “Buried coils” in a lap winding. by the repair process. The next consideration is
the winding type.

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Figure 28. Lap winding showing all coils

with the same span.
Figure 27. Typical concentric coil group. Note
that each coil has a different span.
Single-layer lap windings are sometimes used for
small- to medium-size motors, because the coils
When production volume and economics justify are easier to insert and no separators are required.
it, manufacturers prefer using concentric wind- This allows more room for copper. However, the
ings (Figure 27), which can be machine-wound use of single-layer (full slot) lap windings should
and require less labor. This benefits purchasers by be avoided for 2-pole motors, as they often suffer
keeping the cost of new motors economical. The from poor performance due to harmonics.
drawback is that the turns in each coil of a con- Double-layer lap windings distribute flux
centric winding are not equally effective. through the core better than single-layer lap
Service centers that use predominantly windings. Replacing a double-layer lap winding
hand-winding methods normally find it easier with a single-layer lap winding will certainly re-
to use lap windings because the coils are all the duce motor efficiency, so it is not recommended.
same (see Figure 28). (It takes a winder only Lap windings should be appropriately short-
slightly longer to manually insert a lap winding pitched (i.e., the coil pitch must be less than the
than a 2-layer concentric winding, and about the pole pitch unless the winding has only one coil
same insertion time as a 3-layer concentric.) per group). For more information and more detail
Lap windings are acceptable if the new winding on how to redesign a winding, see the EASA
has the same flux/pole as the original–with one Technical Manual.
exception. A 2-pole concentric winding should be Advantages
maintained because an equivalent lap winding
● Efficiency can be maintained or improved.
would require a very wide pitch and be difficult
Except for a 2-pole concentric winding, the
to insert.
double-layer lap yields the best results.

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 Good Practice Guide to Maintain Motor Efficiency

● MLT can be made the same as, or less than, that That leaves three variables under the control of
of the original winding. the repairer:
● All coils are the same. N - the number of series turns/phase
● All coils have equal exposure to airflow for Kd - the winding distribution factor
cooling. Kp - the chord factor (pitch factor)
● The magneto motive force (MMF) curve more The product of these variables must remain con-
closely resembles a sine wave. stant to satisfy equation (1) above, and this gives
rise to the following important rules for a given
● Phase insulation and coil bracing are more like- winding configuration:
ly to be uniformly placed.
● Increasing the turns, the chord factor, or the
Disadvantages distribution factor reduces the flux.
● Usually none, provided that the conversion is ● Reducing the turns, the chord factor, or the
done correctly. distribution factor increases the flux.
● For further information, see the EASA Technical ● The flux/pole will remain unchanged if the
Manual. product of the chord factor, the distribution
factor, and the turns remains unchanged.
4.3.1 Torque, flux and winding rules
To maintain motor performance, both torque
The following rules are important when changing and efficiency, the flux/pole should remain un-
a winding configuration. changed.
In an induction motor, torque is proportional to 4.3.2 Effect of winding type and design on
flux times current. Both can be affected by chang-
motor performance
es to the winding, and thus both can be affected
by rewinding. The effectiveness of a winding in terms of opti-
mizing motor performance (including efficiency)
The voltage applied to each phase of the motor is
depends both on the type of winding used and its
opposed by (and almost equal to) the back EMF
design, which needs to optimize Kp and Kd such
(induced voltage in a coil caused by the conduc- that fundamental EMF’s per coil are maximized
tors moving through or cutting field magnetic and harmonic EMF’s minimized.
lines of flux). The back EMF is expressed by the
formula: Although this complex subject is outside the
scope of this guide, there are some basic rules
1) E = 4.44 x f x N x F x Kd x Kp that may help service center personnel:
Where: ● Double-layer windings (two coils per slot) give
E = back EMF/phase better results than single-layer windings.
f = frequency ● Some coil arrangements (notably skip slot) give
N = number of series turns/phase much worse results than conventional dou-
ble-layer lap or consequent-pole windings.
F = magnetic flux/pole
● Full-pitched coils generate higher harmonic
Kd = winding distribution factor EMF’s than short-pitched or over-pitched coils.
Kp = winding pitch factor ● In general, double-layer, short-pitched lap
For the purposes of a rewind (other than for a dif- windings give the best results. Single-layer,
ferent voltage or frequency) E and f are constants. short-pitched lap windings are sometimes used
on small/medium size machines but should

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 Good Practice Guide to Maintain Motor Efficiency

never be used to replace a double-layer lap

winding.
4.4 Completing the winding
After fully inserting the winding, connect the
coils and leads to match the original connections
exactly (if a copy or duplicate rewind) or appro-
priately for the replacement lap winding. Use
connection leads that are as large as practical
and mark all of them correctly per the applicable
NEMA or IEC standards. Brace the coil extension
either as the manufacturer’s original winding or
better (i.e., more rigid).
4.5 Winding tests
Figure 29. Measuring the resistance of a coil
Test the winding using the winding resistance group. Note the meter leads are clamped securely
tests and phase balance tests. to bare conductors; also note the ambient
4.5.1 Winding resistance tests temperature thermometer.

When the stator is fully wound, measure and

or unbalanced circuits (which would result in
record the resistance of each phase (or between
circulating currents). Shorted turns will result
leads) as well as the ambient temperature. For
in winding failure, and unbalanced circuits will
future comparison or for comparison to manu-
facturer resistance data, correct the resistance to a increase stator I2R losses.
common reference temperature (normally 25°C) Perform this test after the rewind but before
using the formula: varnish impregnation. The test ensures that all
three phases are wound and connected in the
Rx = x Measured resistance same way. The test works by applying identical
voltage pulses simultaneously to 2 phases of the
Where: winding, or sequentially for all 3 phases, and
Rx = corrected winding resistance recording the voltage decay on an oscilloscope.
Ta = ambient air temperature Identical traces for each phase indicate that the
The resistance of each phase or between leads decay curves for all phases are the same and that
should be within 2% of the average for random the phases are thus identical. Two traces that do
lap windings and may be higher for concen- not appear identical indicate a fault that must be
tric windings (see Figure 29). A high resistance found by inspection (see Figure 30 and Figure 31
between leads could indicate a high-resistance on Page 26).
connection joint. An open stator test in conjunc- Key points–phase balance/surge
tion with thermography should reveal the faulty
comparison tests
connection.
● Perform on completed winding before varnish
4.5.2 Phase balance (or surge comparison) impregnation.
test ● The test compares the decay rate of identical
A surge comparison test will detect unbalanced voltage pulses applied simultaneously for 2
windings, whether they are due to shorted turns winding phases or sequentially for all 3 phases.

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 Good Practice Guide to Maintain Motor Efficiency

The hipot test voltage is intended as a proof test

and should not be repeated. If an additional hipot
test is required, it should be performed at 80% of
the test voltages given above. Subsequent tests
should not exceed 65% of the test voltages given
above.
Note: For reconditioned windings, limit the hipot
test voltage to 65% of the above test values.
4.6 Winding treatment
Figure 30. Satisfactory trace from phase balance/ Impregnating the winding with varnish and sub-
surge comparison test. sequently air drying or baking the varnish until it
is cured serves several purposes:
● It provides a mechanical bond between
conductors.
● It increases the dielectric strength of the
insulation.
● It protects the winding from moisture and
contamination.
● It fills the air spaces between conductors (par-
ticularly in the slots).
The last property is important in terms of motor
efficiency since it helps transfer the heat generat-
ed in the conductors more easily to the stator core
and frame, and thus keeps the winding tempera-
Figure 31. Trace from phase balance/surge ture down. The varnish impregnation process
comparison test indicating a fault. should be carefully controlled to minimize voids
and maximize slot fill. Poor impregnation results
● The trace pattern indicates the phases are in increased winding temperatures, and therefore
identical (okay–identical traces) or different increased resistance and lower efficiency.
(fault–traces do not match).
Lower winding temperature = lower resistance
● The trace pattern gives guidance to type of = lower I2R losses
fault (see equipment manufacturer’s guide).
4.6.1 Varnish and resin types and
4.5.3 Ground test/hipot test
classifications
For windings rated above 250 volts, larger than
Insulating varnishes and resins are classified by
0.5 hp (0.37 kW):
long-term temperature withstand capabilities and
● AC hipot test voltage: 1000 volts + 2 times rated types of material.
voltage (2000V minimum per IEC)
Most modern varnishes and resins are Class F
● DC hipot test voltage: 1.7 times the AC test or H (155°C or 180°C). It is important to use a
voltage given above varnish or resin of at least Class F, even if the
motor is of a lower insulation class (e.g., Class B,

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 Good Practice Guide to Maintain Motor Efficiency

130°C), to compensate for hot spots or unusual ● Fitting a new stator frame onto the stator core
load conditions. with a fit that is too tight (increases rotational
Depending on the treatment used, the goal is to losses in the core) or too loose (inhibits heat
fill the voids among conductors as completely as transfer from the core, increasing stator wind-
possible. Avoid a large buildup of material, how- ing losses).
ever, and remove excess varnish or resin from the ● Failure to clear blocked airways or cooling
bore before placing the stator in the bake oven. ducts.
Also, if the stator is to be impregnated, follow the ● Failure to repair broken cooling ribs, or to re-
varnish or resin manufacturer’s instructions for place missing ones.
pre-heating.
5.4 Bearings and seals
5.0 Mechanical repairs that can ● Selecting incorrect bearings.
affect motor efficiency ● Installing bearings incorrectly.
5.1 Repairs to cores ● Incorrect bearing lubrication (wrong grease,
a) Stator mixed greases, too much grease).
● Grinding damaged surfaces of the core. ● Fitting the wrong type of seal.
● Using undue force to reposition splayed teeth. ● Fitting seals incorrectly.
● Reducing the number of laminations. ● Failure to lubricate (or poorly lubricating) seals.
● Improper restacking. 5.5 Fans and fan covers
b) Rotor ● Installing an incorrect fan, or locating the fan
● Grinding the surface. or fan cover in the wrong position (improper
clearance between the fan and fan cover).
● Machining the rotor with a blunt tool or at
incorrect surface speed (i.e., smearing lamina- ● Not replacing a damaged fan (i.e., missing/
tions together). broken blades).
● Excessive air gap ● Installing an incorrect fan cover.
● Failure to detect or properly repair broken rotor ● Not replacing a broken (damaged) fan cover.
bars or end rings.
● Not ensuring that the fan inlet is free from dirt
5.2 Shaft repairs or other material that might reduce airflow.
● Failure to machine rebuilt bearing seats to the
correct size for the bearings. 6.0 Reassembling the motor
● Shaft replacement using material with different Certain steps of the assembly process can impact
magnetic properties than the original. the motor’s efficiency. (Note: Figure 32 on Page
28 summarizes the distribution of losses for the
5.3 Housing repairs motors in the rewind studies.)
● Repairs to stator frame or end bracket rabbet/ ● Bearing lubrication. A critical step in motor
spigot fits that reduce stator/rotor concentric- assembly is to check the amount of grease in
ity. the bearing cavity. Depending on cavity design,
● Failure to machine a rebuilt bearing housing to shaft-to-bracket clearances and grease viscosity,
the correct size for the bearing, and to concen- the motor may have to run 8 hours or longer to
tricity with the stator bore. purge enough excess grease to reduce friction

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 Good Practice Guide to Maintain Motor Efficiency

effect on the cooling system. Directional fans,

Distribution of losses in of course, must be mounted correctly for the
rewind studies
direction of rotation.
Friction and
windage losses ● Handling. Physical damage to the rotor or
10 - 25%
Stator
stator air gap surface may increase the stray-
core losses load losses. Rough handling can also damage
5 - 20%
the rotor or stator air gap surface, which could
even increase the respective core losses.
● Painting. Finally, make sure ventilation open-
Rotor
I2R losses
ings do not get clogged when the motor is
15 - 20% painted. While this may seem a small point, it
is especially possible when rodent screens are
installed over the openings.
Stator
I2R losses 7.0 Confirming the integrity of the repair
25 - 35%

Stray load losses

Load testing is not always practical, considering
10 - 15% setup time, test time, and power consumption.
Fortunately, it is relatively easy to confirm the
Figure 32. The laminated core, stator windings integrity of the repair by checking for changes in
and rotor account for as much as 75% of total
the biggest loss components–core losses, stator
losses for motors in the rewind studies.
I2R losses, and rotor I2R losses (see Figure 32).
losses. Consequently, it is impossible to predict ● Comparison of before and after burnout core
how long it will take a particular motor to nor- tests proves whether or not the core losses have
malize friction losses. changed. An increase of more than 20% should
be a cause for concern.
● Thrust washers. Particularly in cases where
● An accurate resistance measurement verifies
the bearing is tight in the housing, the assem-
any change in stator I2R losses if the original
bly process may actually preload the bearings,
resistance is known. An increase of more than
increasing friction loss until the motor has ther- 3% should be a cause for concern.
mally cycled several times. Running the motor
for extended periods without full load will not ● Rotor I2R losses should remain unchanged un-
alleviate this condition, as thermal expansion of less the rotor was damaged during the failure
the shaft is minimal until the motor approaches or its diameter was changed by machining.
full-load operating temperature. Ensure that That leaves windage, friction and stray losses.
the thrust washer is installed correctly. ● Windage will not change unless the fan is mod-
● Fans and air baffles. Placement of the external ified or changed. That is easy to avoid.
fan (of TEFC/IP 54, IP 55 motors) can affect the ● Friction should not change if identical bearings
cooling effectiveness and therefore the wind- (and seals if appropriate) with appropriate
ing resistance. For ODP (IP 11, IP 12) motors, fits are used. Substituting sealed bearings for
the relative position of rotor fan blades and open bearings will increase friction. Avoid
the air baffles is also likely to affect winding over-greasing bearings for the same reason.
temperature. Leaving the air baffles out of ● Stray losses are difficult to quantify, but one
the reassembled motor can have a significant area where the repair process can impact them

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 Good Practice Guide to Maintain Motor Efficiency

is during the coil removal. Splayed lamination

teeth will increase stray losses. The more force
it takes to remove the coils, the greater the like-
lihood that teeth will be splayed. To avoid this,
burn out stators at sufficient temperature to
fully break down the insulation and allow for
easy coil removal. All satisfactory results in the
rewind studies were achieved with a burnout
temperature of 700°F (370°C), measured at the
stator core.
Caution: Some lower grade insulation process-
es, such as steam-bluing and waterborne or
lower grade organic varnishes, require extreme
caution and may not be suitable for burnout.

Bibliography
ANSI/EASA Std. AR100-2020: Recommended
Practice for the Repair of Electrical Apparatus.
Electrical Apparatus Service Association, Inc.
St. Louis, MO, 2020.
The Effect of Repair/Rewinding on Premium
Efficiency/IE3 Motors: Full Report. EASA, Inc.
St. Louis, MO, 2020.
IEC Std. 60034-2-1: Rotating Machines–Part 2:
Methods for Determining Losses and Efficiency
for Rotating Electrical Machinery From Tests
(Excluding Machines for Traction Vehicles).
International Electrotechnical Commission.
Geneva, Switzerland, 2014.
IEEE Std. 112-2017: IEEE Standard Test Procedure
for Polyphase Induction Motors and Generators.
Institute of Electrical and Electronics Engi-
neers, Inc. New York, NY, 2017.
NEMA Stds. MG 1-2016 (Rev. 2018): Motors and
Generators. National Electrical Manufacturers
Association. Rosslyn, VA, 2016.

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