Stator Core Testing October 18, 2023

Stator Core Testing

Tom Bishop, P.E.- Senior Technical Support Specialist

Electrical Apparatus Service Association, Inc.
+1 314 993 2220 | [email protected]

Overview

Checking stator core condition is key to assuring that it

does not have hot spots or degradation that could
increase core losses and heating.
This webinar will describe the principles and
performance of core loss testing in the service center.

• Topics Include:
– Principles of core testing
– How to perform core testing using the loop test method
– How to perform core testing using a commercial core
tester
– How to assess the results of a core test
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Objectives

• Upon completing the session, attendees will

be able to:
– Explain the basic principles of core testing
– Explain how to perform a core test using the loop
test method
– Explain how to perform a core test using a
commercial core tester
– Explain how to assess the results of a core test

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How to ask questions

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Stator Core Testing October 18, 2023

Principles of core testing -- theory

• Shorted laminations increase hysteresis and

eddy current losses
– Hysteresis loss: caused by instantaneous change
(increase or decrease) in magnetizing force
• Loss varies directly with frequency
– Eddy current loss: voltages induced in laminations
result in circulating currents in laminations
• Loss varies as square of frequency

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Typical hysteresis curve for lamination steel

2.0

Typical core test

Magnetic Flux Density (T)

1.5
Saturation flux density
1.3
85,000 lines/in2

1.0

M-19 Steel

0 15k 30k

Field Intensity (A-T/m)

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Principles of core testing -- application

• Uses ampere-turns (A-T) to magnetize core

• Developed flux pattern is a ring flux (yellow in
image below)
– Differs from actual winding flux pattern (red in
image below)

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Principles of core testing -- application

• Assess core loss
– Core loss = watts loss per unit of weight
• Example: 3.2 w/lb (7.0 w/kg)
• Assess hot spot temperature rise
– Hot spot = temperature rise above ambient
• Example: 100°F (38°C) hot spot with 70°F (21°C) ambient
= 30°F (17°C) rise
– Apply test flux for relatively long period of time
• Short-time test at overcurrent may not reveal deep-seated
faults
• Use calibrated instruments
– For accurate and repeatable results

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Loop testing overview

• Uses multiple turns of wire to magnetize core

• Relatively low current compared to core tester
• Example: 10 turns at 100 amps = 1000 A-T

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Core tester overview

• Uses single turn of wire to magnetize core

• Relatively high current compared to loop test
• Example: 1 turn at 1000 amps = 1000 A-T

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Loop testing

• Wattage measurement complex compared to

core tester
– Measure input wattage to loop turns
• Subtract loop cable I2R losses from input to determine
core loss
– Example: 300 watts input minus 60 watts cable
loss = 240 watts core loss
• Cable (100 amps)2 x 0.006 ohms = 60 watts cable loss

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Core tester

• Requires only 1 turn through core

– Faster to set up than multi-turn loop
• Wattage measurement much simpler than
with loop test
– Core tester has integral wattmeter

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Core tester procedure

• Instruments on a typical core tester:

– Voltmeter – induced voltage from search coil
– Kilowatt meter – core loss power
– Ammeter – tester turn current

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Hot spot test

• Same method for loop test or core tester

– Measure ambient (room) temperature
– Measure hottest spot(s) in core
– Hot spot temperature rise = hot spot minus
ambient

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How to properly perform a core test

• Determine method: loop test or core tester

– Core tester is preferred
– Use loop test if
• Core tester not available
• Core too large for core tester
• Measure core to be tested
– Length (net, i.e., subtract vents)
– Bore
– Back iron
– Slot depth
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Determine parameters for core test

• Loop test
– Supply voltage
– Supply current
• Lead wire size
– Loop turns
– Induced volts
• Core tester
– Computerized machine provides input and output
parameters

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Loop test procedure

• Wrap calculated loop turns around core

• Wrap single turn search coil around core
• Increase supply voltage and current until
target search coil induced voltage is reached
– Target induced voltage = target flux level attained
– Use true RMS voltmeter for accurate
measurement

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Loop test procedure (continued)

• Hold voltage (flux) at target level

– Larger core à longer energized time
• May be 1 hour or more
• Maintain until hot spot temperature stabilizes
• Measure watts loss and hot spot temperature
• Assess results
– Same criteria for loop test and core tester

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Loop test form

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Loop test setup

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If supply voltage is not variable

• Select lowest available voltage for minimum

turns
Stator loop test Stator loop test
INPUT INPUT
Core length 20.0 Core length 20.0
Inside diameter 13.0 Inside diameter 13.0
Back iron 1.75 Back iron 1.75
Vent width - quantity 0 0 Vent width - quantity 0 0
CALCULATED RESULTS CALCULATED RESULTS
Supply voltage 240 Supply voltage 30
Loop amps 14 Loop amps 110
Loop turns 32 Loop turns 4
Induced volts 7.53 Induced volts 7.53

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If initial core measurement was incorrect

• Use original measurements to compare after

burnout to before
– Assess watts per unit weight
– Assess hot spot temperature rise
• If necessary, repeat after burnout test using
corrected measurements
– Assess watts per unit weight
– Assess hot spot temperature rise
• Applies to both loop test and core tester
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Online loop test calculator

https://easa. com/resources/calculators#459012-loop-test
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Online loop test calculator

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Core tester output report

• Core tester procedure

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How to assess core test results

• Same assessment criteria for both methods

• Target flux density level
– Typically 85 kilolines per sq. in. (1.32 Tesla)
• Watts loss per unit weight
– Suggested limits
• Stator with rolled steel frame 5.0 watts/lb (11.0 w/kg)
• Other stators 4.0 watts/lb (8.8 w/kg)
– Maximum 20% increase pre-winding removal to
post-winding removal
• Reminder: use calibrated instruments
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Assess core test results

• Hot spot temperature rise

– Suggested limit 27°F (15°C)
– Time duration guidelines
• NEMA frames to 440 series
(IEC 310 series) = 15-30 minutes
• Larger frames 45-90 minutes
– Temperature measurement
• Thermal imaging device
• Thermocouple device
• Do NOT use hand – can burn flesh

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Conclusion

• Core damage is not always visually obvious

• Core testing can detect:
– Core damage
– Core degradation
• Core test processes are equivalent
– Loop test
– Core tester
• Assess test results
– Watts loss per unit weight
Hot spot temperature rise
–2023
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How to ask questions

Joined using web browser Joined using web browser
+ Zoom plugin

When prompted, reconfirm

Wait to Submit the audio source you’re using
be called written
on question

Ask
question Ask question verbally
verbally
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Stator Core Testing October 18, 2023

Next webinar

Electric Motors: What’s Inside?

Wednesday, November 15, 2023

12:00 PM CST

Presented by Mike Howell

EASA Technical Support Specialist

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Survey / Recording

Tomorrow, you will be emailed:

• A link to a survey if you would like to provide
feedback.
• A link to a recording of this presentation.

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