Repair Steps for Motors

  1. AFTER RECEIVING MOTORS INTO OUR SHOP, A HARD COPY IS MADE FOR EACH MOTOR. EACH HARD COPY HAS ITS’ OWN NUMBER. THIS NUMBER IS PUT ON EACH PART OF THE MOTOR.
  2. ALL REPAIRS ARE PER EASA ARl00-2015 STANDARDS.
  3. AFTER BREAKING DOWN THE MOTOR, A CAUSE OF FAILURE IS NOTED ON THE HARD COPY.
  4. AFTER IT’S DISASSEMBLED, AN ASSESSMENT OF DAMAGE IS MADE AND THE CUSTOMER IS NOTIFIED OF THE REPAIR COST.
  5. ON CLEAN UP MOTORS; HI-POT TEST AT 500V, AND MEG TEST. THEN, IT’S CLEANED, BAKED AND RETESTED. MEG TEST, SURGE TEST AT 3000V FOR 460V WINDINGS, HI-POT TEST AT 2000V FOR 460V WINDINGS. IF ALL THE TESTS CHECK GOOD, THE STATOR IS THEN DIPPED AND BAKED.
  6. ALL STATORS TO BE REWOUND ARE CUT USING A SAW, NOT AN AIR GUN.
  7. STATORS ARE THEN BURNED OUT IN A TEMPERATURE CONTROLLED OVEN TO REDUCE CORE LOSS IN THE. LAMINATION.
  8. AFTER BURNOUT, ALL WINDING DATA IS RECORDED ON THE HARD COPY.

 

REWIND DEPT.

 

9. ALL STATORS ARE CLEANED AND CHECKED FOR WELDS IN LAMINATION.

10. ALL STATORS ARE CORE-TESTED TO CHECK FOR HOT SPOTS OR BAD IRON IN LAMINATION. PRINTOUTS ARE AVAILABLE TO CUSTOMERS. THIS PRINTOUT IS ATTACHED TO THE HARD COPY AND IS KEPT ON FILE.

11. ALL WINDING DATA IS CHECKED PER EASA BEFORE REWINDING.

12. THE MATERIAL USED IN REWIND IS CLASS H INSULATION.

13. ALL WIRE USED IN REWIND IS INVERTER DUTY, SPIKE RESISTANCE WIRE.

14. COILS ARE MACHINE WOUND WITH ALL THE WIRES INDIVIDUALLY TENSIONED TO OBTAIN UNIFORMITY AND FREEDOM FROM CROSSOVER.

15. PHASE INSULATION IS USED ON A 3 HP AN ABOVE.

16. PHASE INSULATION IS USED HALFWAY BETWEEN GROUP ON 100 HP AND ABOVE.

17. COILS ARE WEDGED WITH FULL-LENGTH TOP STICKS TO HOLD THEM SECURELY IN THE SLOTS.

18. COILS ON BOTH ENDS OF WINDINGS ARE TIED DOWN TO ELIMINATE COIL MOVEMENT.

19. ALL MOTORS ARE REWOUND FOR SINGLE VOLTAGE APPLICATION UNLESS OTHERWISE SPECIFIED.

20. ALL LEADS ARE FLEXIBLE AND TERMINATED WIRE APPROPRIATE SIZED LUGS THAT ARE DIE CRIMPED.

21. AFTER WINDING, ALL STATORS ARE HI-POT TESTED. 460V WINDINGS ARE HI-POT TESTED AT 2000V AND SURGE TESTED AT 3000V BEFORE THE STATORS ARE DIPPED AND BAKED.

22. VARNISH METHODS:

  • 3 HP AND BELOW ARE DIPPED AND BAKED 1 TIME.
  • 5 HP-100 HP ARE DIPPED AND BAKED 2 TIMES.
  • 125 HP AND ABOVE ARE DIPPED AND BAKED 3 TIMES.

23. ALL DRY KILN MOTORS ARE TRIPLE DIPPED AND BAKED AND USE 3M OVERCOAT OVER THE DIP JOB.

 

ASSEMBLY OF MOTORS

 

24. ALL STATORS ARE CLEANED AND BUFFED AFTER BAKING; ANY EXCESS VARNISH IS REMOVED.

25. ALL STATORS ARE HI-POT TESTED, 460V WINDINGS TESTED, AT 2000V AND MEG TESTED.

26. ALL BEARING FITS, SHAFTS AND HOUSINGS ARE CHECKED FOR WEAR, CRACKS, SCOlUNG, AND STRAIGHTNESS. ANY FITS NOT WITHIN TOLERANCE ARE TO BE RESTORED TO SIZE. ALL MACHINE WORK IS DONE IN OUR MACHINE SHOP.

27. ALL INSIDE PARTS ARE PAINTED TO HELP PREVENT RUSTING.

28. NEW GREASE FITTINGS ARE TO BE PUT IN HOUSINGS AND GREASE PUMPED TO MAKE SURE IT IS CLEAN.

29. ALL BEARINGS ARE TO BE REPLACED, USING C3 FIT BEARINGS, OPEN ON ONE SIDE.

30. THE GREASE RESERVOIR SHOULD BE FILLED WITH APPROXIMATELY 1/3 CAPACITY.

31. A BEARING WARMER IS USED TO HEAT BEARINGS BEFORE PLACING ON SHAFT FIT.

32. ALL TEFC MOTORS ARE SEALED IN THE JUNCTION BOX HOLE USING A SEAL COMPOUND.

33. AFTER ASSEMBLING OF MOTORS, ALL MOTORS ARE TESTED.

 

(EXAMPLE: FOR 460V MOTORS)

 

  • HI-POT TESTED 2000 VOLT.
  • MEG TESTED.
  • RUNTEST.
  • NO LOAD AMPS CHECKED.
  • BEARING TEMPERATURE CHECKED.
  • LOAD TEST IF REQUESTED.
  • SHAFTS ARE TO HAVE BLUE LAYOUT PAINT ON THEM TO PREVENT RUSTING.
  • REPAIR TAG ON ALL MOTORS.
  • ALL MOTORS ARE TO BE PAINTED.
  • ALL ABOVE TESTS ARE RECORDED ON HARD COPY.