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AN OVERVIEW OF AC INDUCTION MOTOR TESTING IN ACCORDANCE WITH

BS 4999 PART 143

Article · April 1996

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Lutfi Al-Sharif
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 AN OVERVIEW OF AC INDUCTION MOTOR TESTING
IN ACCORDANCE WITH BS 4999 PART 143
Dr. LUTFI AL-SHARIF

Lift Report [in English & German], March/April 1996

Author’s Note: Although this paper is written around a British Standard, I have felt
that it would be useful to give our German speaking colleagues a flavour of the tests in
accordance with these standards, to let them see how they compare with their
equivalent national standards. I would be very interested to hear from anyone who has
produced anything similar for the German equivalent, or to have a discussion on the
subject.

1. INTRODUCTION
This paper describes a set of tests carried out on an induction motor for a 75 kw
escalator 1. The motor was a squirrel cage induction motor, TEFV (totally enclosed
fan ventilated) to IP55 rating.
Not all the test in here are required by BS 4999. Most of them are based on
part 143; however, some other parts are also used (e.g., part 101). Check references
for a list of the parts used.
The rating of the 75 kw motor is as follows:

Duty type
Type 7Y-AD315M Current 132 A
duration design AMB40
Serial Number GB010168
Frequency 50 Hz Diagram 3DTH
Power 75 kW
COS φ = 0.85 IP55
Drive End Bearing :
Speed 985 rpm Insulation rating F
N319-C3
None Drive End Bearing:
Voltage 416+6-10% 80 °C temperature rise
6314-C3
Connection ∆
Rating MCR Grease UNIREX N3

The motor is also rated to be run by an inverter (VVVF) at synchronous speed

continuously, and at reduced speeds for defined duty cycles. The following data was
on the additional nameplate:

1
These tests were carried out On 22 June 1995, at the factory of Brook Crompton, at Guisely, Yorshire,
England.
 Inverter rated 1000-250 rpm (S2) duty cycle (10 mins)
Constant torque 75kw at 1000 rpm
1000-500 rpm (S1 2) duty cycle

The purpose of the tests was to prove that the motor would deliver the required torque
at starting and running, with realistic losses, and appropriate efficiency. The tests also
ensure that the required level of vibration is not exceeded, and that the insulation of
the motor is more than the minimum value.
This paper describes the details of how the tests were carried out for the 75 kw
motor, in accordance to BS4999, part 143, in addition to other standards and
requirements. It also lists and comments on all the results obtained.

2. THE TESTING SETUP

In order to be able to simulate loading conditions, a DC generator is connected
mechanically to the motor under test. The DC generator output is connected to a
resistor load. The rating of the generator is 325kw. By varying the output current of
the generator, the loading of the motor could be controlled. Figure 1 shows the setup
which was used to load and test the motor. The motor is fed from a 3 phase variable
voltage supply, and is mechanically coupled to a DC generator which acts as a load.
The output of the DC generator is connected to a variable resistor bank which acts as a
load. By varying the value of the resistance, the current flow from the generator can
be varied, and thus the load on the motor is varied. In this way, a variable load to the
motor can be obtained. Several parameters can be measured within this setup, as
follows:

Input voltage Input power factor Loading of the generator

Input current Shaft torque Motor frame temperature
Input real power Shaft speed Inlet air temperature

2
S1 and S2 duty cycles are defined in BS 4999, part 101, section 4.

2
 Variable AC voltage source (3phase)
and measurement system

Voltage, Current, Power Factor

Real Power, Torque, Speed

U V W

Current
Rotor locking device

Speed Torque

Case sensor
M G
Air inlet sensor

Variable
digital Thermometer Resistor Bank

Figure 1: The setup for loading and testing the AC motor.

3. TESTS CARRIED OUT

The tests carried out, were as follows, in the sequence shown here:

• Stator winding (cold resistance) test.

• Temperature rise test.
• Full load test.
• Stator winding hot resistance test.
• Fractional load tests , 75%, 50% 25%.
• 200% overload for 15 seconds.
• Locked rotor tests.
• Speed torque characteristic graph.
• No load test.
• Vibration testing.
• Insulation resistance testing and high voltage testing.
• Direction of rotation.
• Dimensional checking against drawing (and terminal box location).
• Checking the calibration documents for measuring equipment and sensors.
• Bearing checking.

The type testing carried out here was in accordance with the so-called basic-test within
BS 4999, part 143, Table 1. The rest of the sections in this paper describe some of
these tests, not necessarily in the order they were carried out in.

4. FULL LOAD, FRACTIONAL LOAD AND NO LOAD TESTS

The purpose of these tests is to establish how the current, torque, power factor and
speed vary against loading conditions. The tests are carried out at five settings, full

3
load, 3/4, 1/2, 1/4 and no-load 3. The first four of these are carried out with the motor
connected to the generator. All the results for these tests, and for the locked rotor tests
(discussed in a later section), are shown in the figures.
For the no-load test, the motor is disconnected mechanically from any outside
shafts. The purpose of the no-load test is to quantify the no load mechanical losses
(friction, windage and core losses). As the stator copper losses can be calculated from
the resistance of the windings, the no load fixed losses can be calculated by
subtracting the stator copper losses from the total no load losses.
Figure 2 shows the variation of the efficiency and torque against loading. The
torque rises linearly as expected, and achieves its highest values, at 727 Nm. The
efficiency rises as well, due to the nearly fixed nature of the losses, achieving its
highest efficiency at full load (95.4%).

Load tests
800 100

700 90
80
600
70
500
Torque

60
400 50

300 40 Efficiency (%)

30
200
20
100 10
0 0
0 25 50 75 100
Torque (Nm)
Loading (%)
Efficiency (%)

Figure 2: Torque and efficiency against loading.

Figure 3 shows how the power factor and the speed vary with load. As expected, the
power factor has a very low value at no load (around 0.07), and rises to 0.85 at full
load (lagging). The drop in speed is very small, amounting to less than 15 rpm
difference between full load and no load.

3
Fractional load tests are not a requirement of BS 4999 part 143.

4
 Load tests
1 1000
0.9
995
0.8
0.7
Power factor

990
0.6
speed (rpm)
0.5 985
0.4
980
0.3
0.2
975
0.1
0 970
0 25 50 75 100
Power Factor (lagging)
Loading (%)
Speed (rpm)

Figure 3: Power factor and speed against loading.

Figure 4 shows the change in current and power against loading. As expected input
power varies linearly with loading (output power). Current follows a non-linear
relationship.

Load tests
140 120

120 100

100
Current (A)

80
80
60
60 Input Power
40
40

20 20

0 0
0 25 50 75 100
Current (A)
Loading (%)
Power (Kw)

Figure 4: Current and input power against loading.

Throughout the test, some imbalance in the current was encountered between the three
phases, as shown here:

130, 131, 127 A

122, 123, 120 A
These figures are normal.

5
In addition to the full load, fractional load and no-load tests carried out, an overload of
200% was applied for 15 seconds 4. The motor did not change speed abruptly.

5. LOCKED ROTOR TEST AND SPEED TORQUE CHARACTERISTIC

In order to check the starting performance of the motor, the so-called locked rotor test
is carried out. In this test, as the name implies, the rotor is locked in place using a
locking device, and the full rated voltage is applied to the stator 5. The current, input
power and output torque are measured. The locked rotor current (LRC) represents the
starting current of the motor, and the locked rotor torque (LRT) represents the starting
torque. These two measured values are usually expressed as multiples (or
percentages) of the rated current at full load and the rated torque at full load.
These results were calculated against the full load rated values, and the results
are shown here:

Locked Rotor Current (LRC) = 1258/130.23 = 965% of rated current (i.e.,

starting current would be 9.65 times the running current if started
direct-on-line)
Locked Rotor Torque (LRT) = 1750/727= 240% of rated torque (i.e., starting
torque will be 2.35 times the rated torque).

These measured values can be compared with the design values, which are 950% for
locked rotor current, and 240% for locked rotor torque.
Once the locked rotor test was finished, a two channel (XY) plotter, was used
to plot the speed-torque and the speed-current characteristics. The torque sensor was
connected to the Y channel, and the speed sensor was connected to the X channel, and
the motor was run on no-load. The resulting curve is shown in Figure 5. The curve
shows how the torque will vary at different speeds.
The test was then repeated, with a current clamp connected to the Y channel,
and the resulting speed-current curve is also plotted in Figure 5. As expected the
current drops to a low value at near synchronous speed.

4
Not required by BS 4999 part 143.
5
If that is not possible, a fraction of the voltage at a lower frequency can be applied, and the results
adjusted accordingly.

6
 Speed torque characterisitc
3500
1200
3000
Current
1000
2500
Torque (Nm)

800
2000 current
Torque (A)
600
1500

1000 400

500 200

0 0
0 100 200 300 400 500 600 700 800 900 1000
Speed (rpm)

Figure 5: Speed-torque and speed-current characteristics of the 75kw motor.

6. TEMPERATURE RISE TEST

The aim of this test is to show that the motor temperature will stabilise at a certain
level above the ambient temperature, and that this rise is limited to the level required
by the standard. The motor is loaded to its full load 6. Before the test is started, the
cold resistance of the windings is measured. At the beginning of the test, the
temperature of the case, the ambient and the bearing are measured every 15 minutes
(because initially it will change rapidly). However, after the first two hours, the
interval is increased to 30 minutes. The test is stopped when the temperature is
considered to have stabilised (usually taken as the case temperature not changing more
than 2 Kelvin within 30 minutes).
Once the temperature has stabilised, the motor is switched off, and the
resistance of the windings (referred to as the hot resistance) is measured within 90
seconds (for a 75 kw motor, as specified by BS 4999, part 101, clause 15.4.1). The
difference in the value of the resistance, can be used to calculate the increase in the
temperature of the windings (the resistance method as specified in BS 4999, part 101,
15.2.1 and the formula in 15.3.1.1).
Once the hot absolute temperature of the winding is calculated in accordance
to the resistance method, then the winding temperature rise above the ambient is
calculated by subtracting the ambient temperature from the absolute temperature. The
rise should not exceed certain limits specified in Table I, BS 4999, part 101 (for a 75
kw machine, the rise should not exceed 105 K (degrees Kelvin), for an F insulation
machine).
The case temperature and the DE (drive end) bearing temperature have been
recorded, along with the ambient temperature and the input air temperature.

6
When the term full load is used, it refers to the output power being equal to the rating of the machine
at around 75 kw (76.9kw in this case), whereas the input power at that point will be 79.4kw (see clause
8.3, BS 4999, part 101).

7
The case temperature rise is plotted against time, along with the bearing temperature,
as shown in Figure 6. The purpose of the curve is only to prove that the motor has
reached equilibrium, and not to give the absolute value of the temperature of the
windings. The next sub-section shows the method then used to determine the
temperature of the windings.

Temperature rise tests

70

60

50
Temperature (C)

40

30

20

10

0
00:15 00:30 00:45 01:00 01:15 01:30 01:45 02:00 02:30 03:00 03:30 04:00 04:30 05:00
Bearing (DE) temp C
Time elapsed
Frame temp.

Figure 6: Temperature rise tests, showing bearing temperature, and frame temperature
(note that the time axis does not have equal increments).

6.1 Determining Winding Temperature Rise

In order to measure the absolute temperature of the windings at the end of the
temperature rise test, three methods are suggested by BS 4999, part 101. The method
used here is the resistance method, by which the temperature of the motor windings is
calculated by measuring the resistance of the windings before the test and at the end of
the test and applying a formula.

Ambient Resistance of Iron Copper

temperature stator windings temperature temperature
(case) (windings)
Cold (start of 22 °C 0.0303 Ω 22 °C 22 °C
test) (measured) (measured) Assumed equal Assumed equal
to ambient to ambient
Hot (end of 26.7 °C 0.0364 Ω 67.2 °C 73.7 °C
test) (measured) (measured) (measured) (calculated)
Rise above
ambient at the 40.5 K 47 K
end of the test
Table 1: Cold and hot resistance measurements, with ambient temperatures.

8
As the resistance of the winding is quite low (in the milli-ohm range) a standard
ohmmeter is not sufficient, and a special low range ohmmeter has to be used.
Moreover, in order to ensure that the resistance of the test leads does not interfere with
the measurements, four test leads are used, two red and two black, as shown in Figure
7. The terminals of the identical colour leads are shorted at the measurement end.
This allows the instrument to measure the resistance of the test leads, and subtract the
value from the measured resistance of the motor winding which includes the
resistance of the test leads.

RED
Low Resistance
RED

Ohmeter
BLACK
(milliohm range)
BLACK

Motor winding

Figure 7: Winding resistance measurement setup, with four test leads to the motor
windings.

As the motor has three terminals (regardless of its connection, i.e., Υ or ∆), three
measurements can be carried out. In order to allow for the worst case temperature
rise, the highest resistance of the three hot resistance measurements is used, and the
lowest resistance of the three cold resistance measurements is used. This gives the
largest temperature rise.
The formula from BS 4999, part 101 which is used to calculate the
temperature rise is shown below, and it assumes a linear relationship between
resistance and temperature.

t 2 + 235 R 2
= .................... clause 15.311
..
t 1 + 235 R1

(235 used for Copper, 225 for Aluminium)

trise = t2 - ta

where:

t2 = temperature of the winding (cold) at the moment of the initial resistance measurement
t1 = temperature of the winding at the end of the test
ta = temperature of the coolant at the end of the test
R2 = resistance of the winding at the end of the test
R1= resistance of the winding at temperature t1 (cold)

9
Applying the formula in this case, gives:

t 2 + 235 0.0364
=
22 + 235 0.0303

Which gives a value of 73.7 °C for the high temperature. With an air inlet
temperature of 26.7°C, this represents a rise of 40.5 K (degrees Kelvin), which is
within the requirement of 105 K (degrees Kelvin) specified by the standard, and 80 K
(degrees Kelvin) specified in the design. Table 1 shows these results.

7. VIBRATION TESTS
BS 4999, Part 142 specifies the vibration limits (expressed in velocity, mm/sec) for
the various types of motors. The required standard is type S (which limits a 75 kw
motor to 1.12 mm/sec for a speed of 100 rpm, and a shaft height of 315 mm, Table 1,
BS4999, Part 142).
The BS standard also recommends specific measuring points on the drive end
(DE) and the non-drive end (NDE). The results of the measurements carried out on
this motor at the various points are shown in Table 2.

Motor End Velocity (mm/sec)

Horizontal Vertical Axial
DE 0.2 0.5 0.2
7
(Drive End) (measuring point 1) (measuring point 2) (measuring point 3)
NDE 0.3 0.5 N/A
(Non Drive End) (measuring point 4) (measuring point 5) (measuring point 6)
Table 2: Measured vibration values on the motor (measuring point number refers to
BS 4999, part 142, figure 2: Recommended measuring points).

All values are within the required limits (1.12 mm/sec).

8. INSULATION RESISTANCE TESTING

Using a 1000V insulation resistance tester, the resistance between the windings and
the earth was measured, with the thermistor and heater earthed. A value in excess of
200 MΩ was measured.
This was followed by high voltage testing at 2 kV for 60 seconds. The
insulation resistance testing was repeated and a value in excess of 200 MΩ was
achieved again.
The same procedure was followed for the thermistor windings, but at a high
voltage of 1000V.

9. OTHER TESTS
Noise level tests are usually carried out in accordance with BS 4999, part 109, but
these were not carried out in this case. The motor is designed for a level of 73 dBA.

7
Measuring point number, as specified in BS 4999, part 142.

10
 The motor dimensions were checked against the appropriate drawing. All
calibration documents for the measurement equipment were checked and found to be
in order.
The resistance of the thermistors was measured, and checked against the
design value. The heater resistance was also measured and checked against the design
value.
The direction of rotation was checked and confirmed as clockwise at the drive
end, with the correct electrical phase sequence checked by a phase rotation meter.
The temperature of the bearing at the drive end was checked continuously
during the temperature rise test. The bearings during the load tests did not produce
any unusual noise.

10. CONCLUSIONS
The motor performance was satisfactory, and all values measured were well within the
design values, as shown in Table 3.

Design Measured
Temperature rise 80K 40.5K
Locked rotor current 950% 965%
Locked rotor torque 240% 240%
Vibration 1.12 mm/sec 0.5 (max) mm/sec
Full Load current 132 A 130A
Full load torque 727.1 Nm 727 Nm
Table 3: Comparison of measured and design values.

REFERENCES

British Standards Institution, 1987, “BS 4999, 1987: General requirements for
rotating electrical machines”:
Part 101: Specification for rating and performance
Part 102: Methods for determining losses and efficiency from tests
Part 109: Specification for noise levels, including test methods
Part 111: Specification for built-in thermal protection for electric motors rated
660 Volts a.c. and below
Part 141: Specification for standard dimensions
Part 142: Specification for mechanical performance: vibration
Part 143: Specification for tests

11

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