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The Monthly Newsletter of the Electrical Apparatus Service Association, Inc. Volume 41 • No. 7 • July 2007
of the armature
winding, as shown
in Figure 1. The
surge pulse is sent
through one section
of the winding, and
then an equal pulse is
sent through another.
The setup has three
brushes, or probes.
One is common and
is positioned in the
middle of the other
two. The surge pulse
By Cyndi Nyberg
is sent from the
EASA Technical Support Specialist
common to each of
the outside probes. Figure 1. Armature surge test.
In the April 2007 issue of The waveforms
CURRENTS, we covered surge testing resulting from the two surge pulses
anomalies, specifically for AC windings. are then superimposed on an oscil-
The surge test can be used for DC loscope screen and, if they are equal,
windings as well. It can be a useful only a single trace appears. If a second
tool for evaluating armatures and some trace can be seen, as shown in Figure
DC fields. 2, there is some inequality in the two
A note of caution: If a winding does sections being tested. This would
not have a minimum insulation resis- indicate a winding fault such as a
tance per ANSI/EASA AR100-2006, it ground, short or open; or the winding
is not safe to apply an overpotential has unequal turns and the bars spanned Figure 2. Bad surge test pattern.
test (surge or high potential). need to be changed to obtain an equal
Some surge tester manufacturers
Surge testing shunt fields may number of turns across the span; or an
offer a high-current booster attachment
not provide meaningful results if the equalized armature does not have the
to drive the surge pulse through the ar-
surge pulse decays too quickly — if same number of equalizers in the two
mature windings. One manufacturerʼs
it dissipates through only the first few sections being compared.
surge tester has a capacitor in the back
hundred turns. To obtain a test voltage As stated above, the surge test sends
of the unit with a separate lead position
high enough to test every turn would a pulse from the common to the two
for testing armatures; that supplies the
require too high a voltage. That high outside probes. However, the surge pulse
required current for the test.
voltage would overstress the ground- also travels from the common all the
wall insulation. way around the armature (CW) to the Voltage Level
outside of the “left” probe, and from the The bar-to-bar test voltage for the
Surge Testing Armatures
common around in the opposite direction surge test should be about 350-500 volts
DC motor or generator armatures
(CCW) to the “right” probe. Although per bar. However, to avoid over-stressing
can be tested with a surge tester. Al-
the strength of the surge pulse will dis- the groundwall insulation, the maximum
though the winding of an armature is
sipate through the armature winding, total surge test voltage should be 1500
different than that of an AC stator or
a short in the armature will still show volts for armatures rated less than 500
wound rotor, it will still be symmetrical
up on the surge trace. To prove this, try volts, and 2000 volts for armatures rated
if the winding is good.
shorting two bars outside the area under 500 volts and above. The relatively high
Surge comparison testing of an
test; the trace will show a separation. voltage peak of the surge makes it quite
armature, similar to the high-frequency
bar-to-bar test, compares two sections Continued On Page 4
effective for probing the winding for only of the product of the distance
faults like cracked insulation or ther- between parallel plane electrodes. Further information on
mally degraded insulation or insufficient So how does this relate to surge testing of DC machines
voltage creepage clearances. testing? Stated a little differently, can be found in the
Paschenʼs Law means that an applied “Fundamentals of DC
Surge Comparison Test Example
voltage cannot bridge the gap of two Operation and Repair
Each set of bar-to-bar test probes
flat plates (i.e., shorted turns) with a Tips” manual, and in
must span an equal number of bars
certain gap between them until the several articles under
for a meaningful test. Otherwise the
voltage is raised above a minimum “Technical Articles” in
two compared sections will not be
level. This minimum is 350 volts per the “Members Only”
equal. Further, the total number of
turn. A surge test, at the proper voltage section of EASA’s Web
turns being compared must be equal.
level, is the testing method that can do site at www.easa.com.
If the armature has an unequal turn
this between the turns.
sequence, then the surge pattern in
the oscilloscope may show separa- Example:
tion. It may be necessary to adjust the For a 500-volt armature: is rotated slowly by hand, so that all
number of bars spanned to obtain a Surge test voltage = (2 x rated sections of the armature are compared
good pattern, as long as the minimum voltage) + 1000 = (2 x 500) + 1000 to the others.
voltage per turn is maintained. = 2000 volts
Series Fields And Interpoles
Also, when an armature is equal- This voltage applies to a new While the surge test may not be
ized, the sides under test must contain winding as well as one that has been a useful tool for evaluating shunt
an equal number of equalizers. In in service, since this is considered a fields, series fields and interpoles
either case (unequal turns or equaliz- non-destructive test. can be surge tested. The maximum
ers) the result is a pattern that changes Since we need to exceed Paschenʼs surge test voltage should not exceed
at regular intervals. Again, adjustment Law, determine the number of com- the AC high potential test voltage
of the number of spanned bars may be mutator bars spanned on each side of — twice the rated (armature) volt-
necessary. the test probes. The volts per bar will age plus 1000 volts for most DC
Paschen’s Law Requirements be the minimum 350 volts per turn, machines. Use the surge tester to
The test voltage must also meet divided by the number of turns in the compare each series field or inter-
the requirements of Paschenʼs Law winding. If the number of turns is not pole to the one on each side of it.
(i.e., at least 350 volts per turn) known, then assume that it has one That way, each one is tested twice.
without exceeding the test voltage for turn. Using our 2000 volts, and 350 If each pattern on the scope is iden-
the ground insulation. Paschenʼs Law volts per bar for a 1 turn coil: tical, then the fields or interpoles are
states that, at a constant temperature, 2000 volts 2000 volts not shorted.
= = 5.7
the breakdown voltage is a function Minimum volts per bar 350
Synchronous Rotors
Only 5 bars Depending on the number of
should be spanned turns in each rotor pole, the same
on each side of the issues arise with surge testing as
probes. Figure 3 would be present with shunt fields.
4 3 2 1 2 3 4 shows the setup for Further information on testing
5 5 this example. The of DC machines can be found in
surge pulse is sent the “Fundamentals of DC Opera-
from the center tion and Repair Tips” manual, and
through the 5 bars, in several articles under “Technical
and then through the Articles” in the “Members Only”
rest of the wind- section of EASAʼs Web site at
Figure 3. Armature surge comparison test. ing. The armature www.easa.com.
A number of valuable papers and • Rewind Tips for 7kV and Higher
handouts were produced for the education – John Allen
sessions at EASAʼs 2007 Convention in • Sleeve Bearing Repair Tips
Minneapolis, and theyʼre available in a – Chuck Yung
handy compilation called “Select Presen- • Squirrel Cage Rotor Design
tations” on CD-ROM. – Joseph Hillhouse and
Order copies for yourself and your Richard Budzynski
employees using the enclosed form.
• Stator Core Repair and Testing
Now is the time to order while supplies
– Chuck Yung
last. Papers and/or slide presentations
included are: Management Presentations
Technical Presentations • Compensation Strategies
• Dealing with Shaft and Bearing – Michael Marks
Currents • Dealing with Difficult People
– Tom Bishop, P.E. – Bruce Christopher
• Infrared Thermography in the • Have Motors Become Too
Service Center and in the Field Efficient to Replace? • Creating Distinctive Value:
– Cyndi Nyberg – Kitt Butler Building Your Business from the
• Lubrication Technology and Com- • Help Avoid Lawsuits With Outside in
patibility Advance Documentation – Thomas Winninger
– David Slack – Austin Bonnett • Marketing With a Small
• NEMA MG 1-2006: Overview • Improving Profitability 101 (Miniscule?) Budget
and Recent Changes – Albert Bates, Ph.D. – Jerry Peerbolte
– Cyndi Nyberg • Lean Operations for the Service • Preparing for Your Customerʼs
• Perils and Pitfalls of Submersible Center Objections
Pump Repair – Marc Amato and Kevin Harris – Jerry Peerbolte
– Lev Nelik, Ph.D., P.E., APICS • Profitability Planning In-depth • Price Wars: Secrets to Beating the
• Pump-Motor-VFD Issues – Albert Bates, Ph.D. Price Wars Without Destroying
– Lev Nelik, Ph.D., P.E., APICS Profits
Marketing & Sales Presentations
• Repair/Replace: What to Do – Thomas Winninger
• Coordinating Inside/Outside Sales
When the Decision is to Replace for Best Results
– Tom Bishop, P.E. – Mark Freundschuh
Chairman Stratton
Continued From Page 2
Convention In Minneapolis Marks Beginning Of
2007-2008 Terms For Officers, Executive Committee huge benefit to its membership by
Continued From Page 1 helping Sharpen Your Edge over their
competition.
Meanwhile, Iʼm here to be your
of and coordinator of the Technical Stratton and his wife, Linda, have sounding board for a year. I would
Education Committee. two daughters, Christina and Kimberly; like to hear from you. Iʼm in the EASA
He served as international secre- and four grandchildren. Yearbook, listed on the Web site, or
tary/treasurer for 2005-2006 and vice you can contact me through EASA.
chairman for 2006-2007. I will always appreciate your input.
Until next month…
By Dan Parsons, Chair detailed financial results based on of the Operating Performance Report.
Management Services Committee income statement, balance sheet, Itʼs an outstanding value and is a great
A.C. Electric Corp. and operating data of 133 EASA benefit of EASA membership. For those
Auburn, Maine firms that participated. who participated in the survey, but didnʼt
It was distributed free to partici- order a customized Profit Improvement
Results of the 2007 EASA pants. (The survey was disturbed to Profile, you can still order a copy.
Operating Performance Report were all EASA Active members earlier And order form is enclosed with this
distributed in a comprehensive report this year.) issue of CURRENTS.
to participants in June. The Operat- Those who didnʼt participate in
ing Performance Report contains the survey can still purchase a copy
EASAʼs lineup of seminars for of a centrifugal pump, as well as valu- “Principles of Large AC Motors”
2007-2008 (see schedule on Page 12) able insights, shortcuts and methods. covers horizontal and vertical squir-
features the following: “Root Cause Failure Analysis” rel-case induction motors in the 300
“Fundamentals of DC Op- focuses on common as well as un- to 5,000 horsepower range, low and
eration & Repair Tips” covers DC usual types of failures broken down medium voltage; most of the princi-
machine theory and operation, as well by motor components. The seminar ples apply to other sizes as well. The
as repair tips. Topics include testing is intended for anyone interested in material is relevant to North Ameri-
and winding of armatures, fields, in- understanding motor failures, and can and international standards.
terpoles and compensating windings, those who want to serve customers by “Mechanical Repair Fundamen-
machine work, balancing, assembly addressing the cause of failure rather tals of Electric Motors” addresses the
and final testing. The theory portion than the symptom. Each attendee will basic mechanical aspects of motor repair.
is structured so that it can be grasped receive an extensive resource manual Discussion will cover basic materials
by entry-level personnel, while the and CD-ROM containing photos of a and their characteristics, the loading and
overall material is in-depth enough wide range of failures, with the likely stresses involved, the most common
so that those with 30 years or more causes listed, and a clear methodol- failure modes and patterns along with
experience will benefit. ogy for confirming the probable cause recommended repair practices as they
“Centrifugal Pump Repair” in- of each failure. relate to applications.
cludes actual teardown and assembly
EASA and the Association Education attend together. The training will be pre- the seminar, go to EASAʼs Web site
Alliance (AEA) are working together sented by Don Buttrey of Sales Profes- and open “The Habit of Selling” icon.
once again to bring you “The Habit of sional Training, LLC. If you have questions, call EASA
Selling.” The 2 1/2 day seminar is sched- To register, call the AEA directly at (314) 993-2220 or e-mail at
uled October 2-4 in Dayton, Ohio. at 410-263-1014 or complete the easainfo@easa.com.
The highly rated seminar is designed enclosed form and fax it to the AEA at
for salespeople and sales managers to 410-263-1659. To find out more about
EASA is a
New Active Members Co-Sponsor of:
EASA welcomes the following companies,
which became Active members within the past year.
Company _________________________________________________________________________________________________________________
Address _________________________________________________________________________________________________________________
City/State/Prov. _ ______________________________________ Zip ___________________ Country ________________________________________
Telephone ( ) _ ________________________________________ Fax ( ) ______________________________________________________
Ordered By _ ___________________________________________ Title _ ______________________________________________________________
Web site _________________________________ Co. E-mail __________________________ Your E-mail _ ____________________________________
* Prices effective 7/1/07 and include shipping in the U.S. only. Missouri residents add 7.575% sales tax. Orders received without payment are subject to a $2.00 service charge. Items sold off the North American
continent (including Hawaii and Puerto Rico) are sold F.O.B. St. Louis, with air shipping charge, plus insurance charge (if required) added to the invoice. Such purchasers agree to pay air freight, plus insurance
charge (if required). Payable in U.S. funds only. No refunds; exchanges only on such products determined by EASA to be defective. All items and prices subject to change without prior notice. If paying by bank wire,
add $25 fee to total (or you will be invoiced for such).
Please send _______ copies of “Select Presentations” on CD-ROM at $30 (U.S.) each (Active, Associate). (Privileged/Honorary is $60; Nonmember is $90.)
Company _____________________________________________________________________________________________
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Telephone ( ) ____________________________ Fax ( ) ______________________________________________
Ordered By _______________________________ Title ________________________________________________________
Web site ___________________________ Co. E-mail ______________________ Your E-mail ___________________________
* Prices effective 7/1/07 and include taxes and shipping in the U.S. only. Missouri residents add 7.575% sales tax. Note: Minimum order is $10. Orders received without payment are subject to a $2.00 service charge.
Items sold off the North American continent (including Hawaii and Puerto Rico) are sold F.O.B. St. Louis, with air shipping charge, plus insurance charge (if required) added to the invoice. Such purchasers agree to pay
air freight, plus insurance charge (if required). Payable in U.S. funds only. No refunds or exchanges after 90 days. All items and prices subject to change without prior notice. Credit Card orders from nonmembers must
total at least $50; otherwise, payment must be made by check prior to shipment. If paying by bank wire, add $25 to total (or you will be invoiced for such).
AL APPA
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ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC.
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EA SA 1331 Baur Blvd. • St. Louis, MO 63132-1986 • 314-993-2220 • Fax 314-993-1269 • www.easa.com
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A Reliable Solutions Today!
Version707BP-30C
Plan A Strategy For Higher Profits
Using The 2007 OPERATING
PERFORMANCE REPORT
Order your copy of this valuable report based Report Available
on input from other EASA members! (Survey For EASA
participants already have received their copy.) Members Only
Non-Participant Cost for the 2007 Operating Performance Report is $125. (Delivered by e-mailed PDF.)
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Ordered By _________________________________ Title ________________________________________________________
Web site _____________________________ Co. E-mail ______________________ Your E-mail __________________________
* Prices effective 7/1/07 and include taxes and shipping in the U.S. only. Missouri residents add 7.575% sales tax. Note: Minimum order is $10. Orders received without payment are subject
to a $2.00 service charge. Items sold off the North American continent (including Hawaii and Puerto Rico) are sold F.O.B. St. Louis, with air shipping charge, plus insurance charge (if
required) added to the invoice. Such purchasers agree to pay air freight, plus insurance charge (if required). Payable in U.S. funds only. No refunds or exchanges after 90 days. All items
and prices subject to change without prior notice. Credit Card orders from nonmembers must total at least $50; otherwise, payment must be made by check prior to shipment.
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