www.allsyllabus.

com

UNIT - 4
TESTING OF DC MACHINES
Testing of DC machines can be broadly classified as
i)

Direct method of Testing

ii)

Indirect method of testing

DIRECT METHOD OF TESTING:

In this method, the DC machine is loaded directly by means of a brake applied to a water cooled
pulley coupled to the shaft of the machine. The input and output are measured and efficiency is
determined by =




. It is not practically possible to arrange loads for machines of large

la
bu
s.
co
m

capacity.
INDIRECT METHOD OF TESTING:

In this method, the losses are determined without actual loading the machine. If the losses are
known, then efficiency can be determined. Swinburnes test and Hopkinsons test are commonly
used on shunt motors. But, as series motor cannot be started on No-load,these tests cannot be

BRAKE TEST: is a direct method of testing.

w
.a
lls

(i)

yl

conducted on DC series motor.

In this method of testing motor shaft is coupled to a

Water cooled pulley which is loaded by means of weight

as shown in figure4.1.



 = suspended weight in kg

 = Reading in spring balance in kg



R = radius of pulley

N = speed in rps
V = Supply voltage
Figure 4.1

I = Full Load Current

Net pull due to friction = (  ) kg
= 9.81 (  ) Newton . 1
Shaft torque  =   )  .

vtu.allsyllabus.com

www.allsyllabus.com

= 9.81 (  )    2
Motor output power =   2   Watt
=   )  2   watts . 3
Or 9.81 (  )  2   watt.
= 61.68 N (  )  .. 4
Input power = VI watts . 5
Therefore efficiency =




.   ! " # $
%&

This method of testing can be used for small motors only because for a large motor it is difficult to

arrange for dissipation of heat generated at the brake.

.a

lls

yl
la

bu

s.
co

(ii)Swinburnes Test:

Figure 4.2

This test is a no load test and hence cannot be performed on series motor. The circuit connection is
shown in Figure 4.2. The machine is run on no load at rated speed which is adjusted by the shunt
field resistance.
ADVANTAGES
1. Economical, because no load input power is sufficient to perform the test
2. Efficiency can be pre-determined
3. As it is a no load test, it cannot be done on a dc series motor

vtu.allsyllabus.com

www.allsyllabus.com

DISADVANTAGES
1. Change in iron loss from no load to full load is not taken into account. (Because of armature
reaction, flux is distorted which increases iron losses).
2. Stray load loss cannot be determined by this test and hence efficiency is over estimated.
3. Temperature rise of the machine cannot be determined.
4. The test does not indicate whether commutation would be satisfactory when the machine is
loaded.
IO = No load current; Ish = shunt field current
Iao = No load armature current = (Io - Ish)
V= Supply Voltage

co
m

No load input =VIo watts.

Iron losses in the core

(ii)

Friction and windings loss and

(iii)

Armature copper loss.

la

bu

(i)

s.

No load power input supplies

yl

Let I = load current at which efficiency is required

lls

Ia = I Ish if machine is motoring; I + Ish if machine is generating

.a

Efficiency as a motor:

Input = VI; Ia2ra = (I- Ish)2ra

Constant losses Wc = VIo (Io Ish)2ra 7

Total losses = (I- Ish)2ra + Wc

Therefore efficiency of motor =

"'
(


)* *"*,- ./012

;=

%&

. 8

EFFICIENCY OF A GENERATOR:
Output = VI
Ia2ra = (I+Ish)2ra
Total losses = Wc+(I+Ish)2ra .. 9



Efficiency of generator =
0'
( = %&0&0&

%&

34

# 5 0
6

10
7

vtu.allsyllabus.com

www.allsyllabus.com

1. A 220 V DC shunt motor at No-load takes a current of 2.5 A. the resistance of the armature
and shunt field are 0.8 and 200 respectively. Estimate the efficiency of the motor when the
input current is 32 A.
SOLUTION: No-load input = 220 x 2.5 = 500 W
8 =

9
99

= 1.1 A;8:
= 2.5 1.1 = 1.4 >;8:
?: = 1.4) X 0.8 = 1.6 W

Constant losses = 550 1.6 = 548.4 W

When input current is 32 A, Ia = 32 1.1 = 30.9 A
8: ?: = 30.9)  0.8 = 764 ; Total losses = 764 + 548.4 = 1315 W

Therefore output = (220 X 32) 1315 W

Therefore =

"'
(


= 81.3 %

la
bu
s.
co
m

Input = 220 X 32

2. A 440V D.C Shunt motor takes no load current of 25A. The resistance of shunt field and
armature are550 & 1.2 respectively. The full load line current is 32A. Determine the full
load output &efficiency of the motor.
%

yl

SOLUTION:input on no load= VI=4402.5=1100W

SOLUTION:
ZZ9

34

w
.a
lls

8 = $ = [[9 = 0.8A;8 = 8 + 8: , therefore, 8: = 8 8 = 2.5-0.8=1.7A

ef gfh ?i?j ki gfll = 8: ?: = (1.7)21.2=3.468W

kfele gfll = meni fe ef gfh ef gfh ?i?j ki gfll= 1100-3.468=1096.532W

8o =32A, 8: = 32-0.8=31.2A; Armature copper loss = (31.2)  1.2 = 1168.128 
tuvwx"yz,,{,

(ZZ9| )" Z.

Total losses = 1168.128 + 1096.532 =2264.66W

tuvwx

(ZZ9| )

100 = 83.9 %

2. A 500 V DC shunt motor when running on No-load takes 5 A. Armature resistance is 0.5 and
shunt field resistance is 250. Find the output in kW and of the motor when running on full
load and taking a current of 50 A.

vtu.allsyllabus.com

www.allsyllabus.com

(iii) Hopkinsons Or Regenerative Or Back To Back Test:

This is a regenerative test in which two identical DC shunt machines are coupled mechanically and
tested simultaneously. One of the machines is run as a generator while the other as motor supplied by
the generator. The set therefore draws only losses in the machines. The circuit connection is shown
in Figure 4.3. The machine is started as motor and its shunt field resistance is varied to run the motor
at its rated speed. The voltage of the generator is made equal to supply voltage by varying the shunt
field resistance of the generator which is indicated by the zero reading of the voltmeter connected
across the switch. By adjusting the field currents of the machines, the machines can be made to
operate at any desired load with in the rated capacity of the machines
ADVANTAGES:
The two machines are tested under loaded conditions so that stray load losses are

i.

Power required for the test is small as compared to the full load powers of the two

s.

ii.

co

accounted for.

machines. Therefore economical for long duration tests like Heat run tests.
Temperature rise and commutation qualities can be observed.

iv.

By merely adjusting the field currents of the two machines the two machines can be

yl
la

bu

iii.

loaded easily and the load test can be conducted over the complete load range in a short

.a
lls

time.
DISADVANTAGES:

Availability of two identical machines

ii.

Both machines are not loaded equally and this is crucial in smaller machines.

iii.

There is no way of separating iron losses of the two machines which are different because

i.

of different excitations.
iv.

Since field currents are varied widely to get full load, the set speed will be greater than
rated values.

The efficiency can be determined as follows:

vtu.allsyllabus.com

www.allsyllabus.com

co

CIRCUIT DIAGRAM

Figure 4.3

Motor input = V(I1+I2)

----------------- (a)

la

Generator output = VI1

bu

s.

V= supply voltage

yl

If we assume both machines have the same efficiency , then,

lls

Output of motor = x input = x V (I1+I2) = input to generator

Therefore, = ~

VI1 = 2V(I1+I2)

Equating (a) and (b),

.a

Output of generator = x input = x V (I1+I2) = 2V(I1+I2)-----(b)

&!

&!0&#

11

Armature copper loss in motor = (I1 + I2 I4)2ra

Shunt field copper loss in motor = VI4
Armature copper loss in generator = (8 + 8| ) ?:
Shunt field copper loss in generator = VI3
Power drawn from supply = VI2
Therefore stray losses = VI2 - (8 + 8 8Z ) ?: + 8Z + (8 + 8| ) ?: + 8| = W (say) 12

vtu.allsyllabus.com

www.allsyllabus.com

Stray losses/motor =

13

Therefore for generator

Total losses = (8 + 8| ) ?: + 8| +

Output = VI1, therefore generator = %&

= Wg (say) . 14

%&!

!0



=
0'
( .. 15

For motor,
Total losses =(8 + 8 8Z ) ?: + 8Z +

=  (l)

Input to motor = V(8 + 8 )

16

la
bu
s.
co
m

%(&! 0&# )"

%(&! 0&# )

w
.a
lls

yl

Therefore motor =

vtu.allsyllabus.com

www.allsyllabus.com

la
bu
s.
co
m

ALTERNATIVE CONNECTION:

Figure 4.4

The Figure 4.4 shows an alternate circuit connection for this test. In this connection the shunt field
windings are directly connected across the lines. Hence the input current is excluding the field

Motor armature copper loss =(8 +8 ) ?:

w
.a
lls

Generator armature copper loss = 8 ?:

yl

currents. The efficiency is determined as follows:

Power drawn from supply = VI1

Stray losses = 8 (8 +8 ) ?: 8 ?: = W(say) .. 17

. 18

Stray loss/motor =

MOTOR EFFICIENCY: motor input = armature input + shunt field input

= V(8 +8 ) + 8|

Motor loss = Armature copper loss + Shunt copper loss + stray losses = (8 + 8 ) ?: + 8| +

Therefore motor =


5 "

5 '
(


5 

. 20

Generator efficiency : Generator output = VI2

Generator losses = 8 ?: + 8Z +

generator =

%&#

%&# 0 ((5:
5 '
(

21

. 22

vtu.allsyllabus.com

.. 19

www.allsyllabus.com

1. The Hopkinsons test on two similar shunt machines gave the following Full load data.Line
voltage = 110 V; Line current = 48 A; Motor armature current = 230 A; Field currents are 3 A and
3.5 A; Armature resistanceof each machine is 0.035 ; brush drop of 1V/brush; Calculate the

Figure 4.5

SOLUTION:

s.

Motor: Armature copper loss = (230  0.035 = 1851.5 W

co
m

efficiency of each machine.

bu

Brush contact loss = 230 X 2 = 460 W

Total copper loss = 2312 + 330 = 2642 W

yl

Shunt field copper loss = 110 X 3 = 330 W

la

Total armature copper loss = 1851.5 + 460 = 2312 W

lls

Generator: Generator armature copper loss = (188.5)2 x 0.035 = 1244 W

.a

Brush contact loss = 188.5 X 2 = 377 W

Total armature copper loss = 1244 + 377 = 1621 W.

Shunt field copper loss = 110 X 3.5 = 385 W

Therefore total copper loss = 1621 + 385 = 2006 W

Total copper loss for set = 2642 + 2006 = 4648 W

Total input = 110 X 48 = 5280 W
Therefore stray losses = 5280 4648 = 632 W
Stray losses/machine =

|

316 

Total losses = 2312 + 330 + 316 = 2958 W

Motor input = 110 X 233 = 25630 W. Motor output = 22672 W


motor =

[|9

= 88.45%

generator: total losses = 1621 + 385 +316 = 2322

Output of generator = 110 X 185 = 20350 W.
Therefore =

9|[9

= 89.4%

9|[90 |

vtu.allsyllabus.com

www.allsyllabus.com

2. In a Hopkinsons test on a pair of 500 V, 100 kW shunt generator. The following data was
obtained:Auxiliary supply 30 A at 500 V; Generator output current 200 A; Field current 3.5 A and
1.8 A; ra = 0.075 for each machine; voltage drop at brushes = 2 V/machine; calculate the

Figure 4.6

bu

SOLUTION:

s.
co

efficiency of the machine as a generator.

yl
la

Motor armature copper loss = (230)2 X 0.075 + 230 X 2 = 4428 W

Motor field copper loss = 500 X 1.8 = 900 W

lls

Generator armature copper loss = (200)2 X 0.075 + 200 X 2 = 3400 W

.a

Generator field copper loss = 500 X 3.5 = 1750 W.

Total copper loss for 2 machines = 4428 + 900 + 3400 + 1750 = 10478 W

Power drawn = 500 X 30 = 15000 W

Therefore stray loss for the two machines = 15000 10478 = 4522 W.
Stray loss / machine =

Z[

= 2261 W

Therefore total losses in generator = 3400 + 1750 + 2261 = 7411 W

Generator output = 500 X 200 = 100000 W
Therefore generator =

99999
999990Z

= 93.09 %

3. In a Hopkinson test on 250 V machine, the line current was 50 A and the motor current is 400 A
not including the field currents of 6 and 5 A. the armature resistance of each machine was 0.015.
Calculate the efficiency of each machine.

vtu.allsyllabus.com

www.allsyllabus.com

SOLUTION:
Motor armature copper loss = (400)2 X 0.015 = 2400 W

s.

Generator armature copper loss = (350)2 X 0.015 = 1838 W

co
m

Figure 4.7

bu

Input power = 250 X 50 = 12500 W

la

Ws = stray losses = 12500 (2400 + 1838) = 8262 W; Ws per machine =

 

4130 

yl

Motor efficiency: armature copper loss of motor = 2400 W;

lls

Motor field copper loss = 250 X 5 = 1250 W; Total motor losses = 2400 + 1250 + 4130 = 7780 W

9 [9

9 [9 "9

= 92.3 %

Therefore =

.a

Motor input = 250 X 400 + 250 X 5 = 101250 W.

Generator efficiency:

Generator armature copper loss = 1838 W;Generator field copper loss = 250 X 6 = 1500 W
Total losses of Generator = 1828 + 1500 + 4130 = 7468 W
Generator Output = 250 X 350 = 87500 W
Efficiency of Generator =

[99
[99 0Z

 100
91.5%

4. The following test results were obtained while Hopkinsons test was performed on two similar DC
shunt machine. Supply voltage = 250 V; Motor Field Current = 2 A; Generator Field Current = 2.5A;
Generator Armature Current = 60 A; Current taken by the two armature from supply = 15 A;
Armature Resistance/Machine = 0.2; Calculate the efficiency of motor and generator under these
conditions.

vtu.allsyllabus.com

www.allsyllabus.com

bu

Figure 4.8

s.

co

(iv) Field test for series motor:

la

Figure 4.8 shows the circuit for fields test. This test is applicable to two similar series motor. One of

yl

the machine runs as a motor and drives a generator whose output is wasted in a variable load R.
Both machine field coils are in series and both run at same speed so that iron and friction losses are

lls

made equal.

.a

Load resistance R is varied till the motor current reaches its full load value.

I1 = Motor current

V = Supply voltage

V2 = Generator terminal voltage

I2 = Load current
Input = VI1 and output = V2I2
Ra and Rse = hot resistances.
Total losses in the set Wt = VI1 V2I2 .... 23
Armature and Field copper losses Wc = (Ra + 2 rse) I12 + Ia2Ra 24
Stray losses forthe set = Wt Wc ..25

vtu.allsyllabus.com

Stray losses per machine Ws =

"

www.allsyllabus.com
7

26

Motor efficiency: input = V1I1

Losses = (: + ( )8 +  =  (l)
motor=

%&! 0
%&!

27

Generator efficiency: of generator is of little use, because its field winding is separately excited
Generator output = VI2
Field copper loss =8 ?(
Armature copper loss = 8 ?:

%&#

%# 0

29

s.

generator =

co
m

Total losses = 8 ?( + 8 ?: +  = Wg (say). 28

bu

1. A test on two coupled similar tramway motors with their fields connected in series, gave the
following results when one machine acted as a motor and the other as a generator.Motorarmature

la

current = 56 A; Armature voltage = 550 V; Voltage drop across the field winding = 40V; Generator:

yl

armature current = 44 A; Armature voltage = 400 V; Field drop across the field winding = 40V;

.a

lls

Resistance of each armature = 0.3; Calculate the efficiency of motor and gearing at this load.

Figure 4.9

vtu.allsyllabus.com

www.allsyllabus.com

SOLUTION:
Total input = 630 X 56 = 35280 W
Output = 400 X 44 = 17600 W
Total losses = 35280 17600 = 17680 W
Z9

Rse = [ = 0.714
Total copper loss = (0.3 + 2 X 0.714) 562 + 442 X 0.3 = 6006 W
Therefore stray losses = 17600 6006 = 11674 W
Stray losses per motor =

Z

= 5837 W

co
m

Motor efficiency: motor input = 590 X 56 = 33040 W

Armature circuit copper loss = (0.714 + 0.3) 562 = 3180 W

Total losses = 3180 + 5837 = 9017 W

||9Z9 " 9
||9Z

 100 = 72.7%

la

Therefore efficiency =

bu

s.

Stray losses = 5837 W

lls

yl

Generator efficiency: Armature copper loss = 0.3 X 442 = 581 W

Series field copper loss = 40 X 56 = 2240 W.

.a

Stray losses = 5837 W

Therefore total losses = 581 + 2240 + 5837 = 8658 W

Output = 400 X 44 = 17600 W

99

Therefore generator = 99 0 [  100 = 67%

3. A fields test on two similar series machines gave the following data; Motor: Armature current:

60A; Voltage across armature: 500V; Voltage across field: 40V; Generator: Terminal voltage: 450V;
Output current 46A; Voltage across field:40V; Armature resistance of each machine is 0.25.
Calculate the efficiency of both the machines.
SOLUTION:
SOLUTION:
Total input = 58060=34800W
Output =45046=20700W
Therefore total losses in 2machines = 34800-20700=14100W

vtu.allsyllabus.com

www.allsyllabus.com
2

Total cu loss = (0.25+ 20.67)(60) + (46) 2=6253W

Stray losses of the set = 14100-6253= 7847W
Z

=3923.5W

la

bu

s.

co
m

Stray loss per machine =

Figure 4.10

yl

Efficiency of Motor;

lls

Motor input= motor armature voltage armature current =540 60 =32400W

.a

Armature cu loss = (0.25 + 0.67) (60)2= 3312W

32400"7235.5
32400

= 77.67 %

of motor =

Total losses = 3312 + 3923.5 =7235.5W

Efficiency of Generator; generator output= 450 46 =20700W

Armature cu loss = (0.25) (46)2= 529 W
Series field cu loss = 40 60 =2400W
Total losses = 2400 + 529 + 3923.5 =6852.5W
of generator =

20700
2070006852.5

X 100 = 75.1 %

vtu.allsyllabus.com

www.allsyllabus.com

(V)

Retardation or running down test:

B

N
P

Figure 4.12

Figure 4.11

co
m

This method is applicable to shunt motors and generators and is used for finding the stray losses. If
armature and shunt copper losses are known for a given load, efficiency can be calculated. The
circuit is shown in figure 4.11.

s.

Machine is speeded up slightly beyond its rated speed and then supply is cut off from the

bu

armature while keeping the field excited. Armature will slow down and its kinetic energy is

.a
l

ls

I = Moment of inertia of the armature

yl

Kinetic energy of the armature = 8

la

needed to meet rotational losses. i.e., friction and windage losses.

Rotational losses;

N = Rate of loss of K.E.

= Angular velocity.

Rate of loss of Kinetic energy W =

IXW

30

Two quantities need to be known

(i)

Moment of Inertia I

(ii)

(i)

or ( because ))

Finding : The voltmeter V in the circuit shown in Figure 4.11 is used as speed indicator

by suitably graduating it because E . when the supply is cut off, the armature speed and

vtu.allsyllabus.com

www.allsyllabus.com

hence voltmeter reading falls. Voltage and time at different intervals are noted and a curve is
drawn between the time and speed as shown in Figure 4.12.
In the Figure 4.12 AB - tangent drawn at P
There fore

W=8

(5)

(()


9

W = I 
9


9




31

W = 9 8. .  = 0.011 X I X N X

co

(ii) Finding Moment of Inertial I: There are two methods of finding the moment of inertia I
(a) I is calculated:

Slowing down curve with armature alone is calculated.

(iii)

For any given speed,

, and  are determined as before.

#

la

bu

A fly wheel is keyed to the shaft and the curve is drawn again

yl

(ii)

s.

(i)

Therefore W = 9 8. .  --- (32) 1st case



lls

.a

W = 9 (8 + 8 ).
--- (33) 2nd case

#

Equation (32) = Equation (33), losses in both the cases will be almost same.

h
h 8 + 8 h
h
= (8 + 8 )
.
=
h
h
8
h
h

&0 &!
&

= 

I = 8 X 

#

! " #

34

(b) I is eliminated: In this method, time taken to slow down is noted with armature alone and then a
retarding torque is applied electrically i.e., a non inductive resistance is connected to the armature.
The additional loss is 8: (: + )or8: .

Let W1 be the power then

W=(9 )2 IN

!

35

vtu.allsyllabus.com

W + W1 = (

2

) IN
9
#

www.allsyllabus.com

36; if dN is same.

!

=rate of change of speed without electrical load

#

=rate of change of speed with electrical load

1 0 1
1

37 or

1 0 1
1

= !or W= W1 

#

! " #

or W= W1 

#

! " #

. 38

1. A retardation test is made on a separately excited. DC machine as a motor the induced

voltage falls from 240V to 225V in 25 secs on opening the armature circuit & 6 secs on
suddenly changing the armature connection from supply to a load resistance taking 10A

(average). Find the efficiency of the machine when running as a motor& taking a current of

Iav = 10A

la
bu
s

Power absorbed = w = 232.5 X 10 = 2325w

t1 =30sec & t2= 6sec, W = stray loss.
Therefore W = W X 

#

! " #

.c

SOLUTION:
Average voltage across load = 240+225/2 = 232.5

om

25A on a supply of 250V. The resistance of its arm is 0.4 & that of its field winding is 250.

; therefore W = 2325 X [" = 734.1w.

[9

yl

Input current = 25A; Ish = [9= 1A therefore Ia = 25 - 1= 24A

lls

Armature Current loss = (24)2 X 0.4 = 230.4 w,

.a

Shunt current loss = 250 X 1 = 250w

Therefore total losses = 734.1 + 230.4 +250 = 1215 w

Input = 25 X 25 = 6250w output = 6250 -1215 = 5035w

[9|[

Therefore efficiency =  [9= 0.806 or 80.6%

2. In a retardation test on a separately motor, the induced emf in the armature falls from 220V
to 190V in 30seconds on disconnecting the armature from the supply. The same fall takes place

in 20seconds if, immediately after disconnection, armature is connected to a resistance which

takes 10A (average) during this fall, find the stray losses of motor.
SOLUTION:

W = stray losses
Average voltage across resistance =

9909

= 195

Average current = 10A; Power absorbed W = 1950w

#

! " #

; W = 1950  |9" 9 = 3900w.

vtu.allsyllabus.com

www.allsyllabus.com

(2) A retardation test is carried out on a 1000rpm D.C machine. The time taken for the speed
to fall from 1030 rpm to 970rpm is (a) 36secs with no excitation. (b) 15secs with full excitation
& (c) 9 seconds with full excitation & the armature supplying an extra load of 10A at 219V.
Calculate (1) The moment of inertia of the armature is kg.m2. (2) Iron loss and (3)
Themechanical losses at the mean speed of 1000rpm.
SOLUTION:

(i) When the arm slows down with no excitation its kinetic energy is used to over come
mechanical losses only (no flux, no Iron loss)

(ii) With excitation, Kinetic Energy is used to supply mechanical & iron losses ie., stray losses.
(iii) If Moment of Inertia is in kgm2 unit then rate of loss of energy is in Watts.

Mechanical loss Wm = 9 I N

9

9

Similarly Ws = 9 I N [ watts.

Ws = w X

#

! "#

= 219 X 10 X

["

------ (2)

.c

------- (1)

la
bu
s

Wm = 9 I N | watts

om

dN = 1030-970 = 60rpm, dt = 36seconds, N = 1000rpm.

= 3285 watts

9

Using equation (2) 3285 = 9  8  1000  [ ; I = 75 kgm2

Wm = 3.285 X

|

[

= |

= 1369 watts

yl

[

lls

Dividing (1) by (2) , we get

.a

& iron loss =Ws-Wm = 3285-1369 = 1916watts.

4. In a retardation test on a DC motor with its field normally excited the speed fell from 1525 to

1475 rpm in 25seconds. With an average load of 1.0kw supplied by the armature, the same

speed drop occurred in 20seconds. Find out the Moment of Inertia of the rotating parts in kgm2.

SOLUTION:

W = 9 2 I N




x

& W =W X"

W= 1kw = 1000watts & t1 = 25 seconds& t2 = 20seconds

9

W = 1000 X [" 9 = 4000w

N = 1500rpm (average speed); dN = 1525-1475 = 50rpm

[9

dt = 25 ; 4000 = 9  8  1500 X
[
I = 121.8 kg-m2.

vtu.allsyllabus.com