EASA AC Redesign Manual V.0214-0815 PDF

AC Motor
Redesign
Electrical Apparatus Service Association, Inc.

1331 Baur Boulevard St. Louis, Missouri 63132
314-993-2220 Fax: 314-993-1269 www.easa.com
AC Motor
Redesign

Electrical Apparatus Service Association, Inc. 1990-2014 i
The ElectroMechanical Authority 314-993-2220 Fax: 314-993-1269 www.easa.com
Copyright 1990-2014
St. Louis, Missouri
All rights reserved.
ii Electrical Apparatus Service Association, Inc. 1990-2014

Table Of Contents
Chapter Page
Preface.................................................................................................................v
1. Wire Size Change........................................................................................1
2. Voltage Change............................................................................................6
3. Horsepower Or Kilowatt Change................................................................9
4. Frequency Change.....................................................................................14
5. Phase Change............................................................................................18
6. Circuit Change...........................................................................................20
7. Span Or Chord Factor Change..................................................................23
8. Winding Connection Change....................................................................27
9. The Master Formula..................................................................................29
10. Converting Concentric Windings To Lap Windings.................................32
11. Converting Lap Windings To Concentric Windings.................................38
12. Notes On Pole Changing...........................................................................42
13. Decreasing Speed By Increasing Poles.....................................................49
14. Increasing Speed By Decreasing Poles.....................................................57
15. Single-Speed To Two-Speed, One Winding..............................................65
16. Single-Speed To Two-Speed, Two Winding..............................................72
17. Developing A Winding For A Bare Core...................................................81
18. Strengthening Or Weakening A MotorShort Method............................89
19. Determining The Proper Connection.........................................................94
20. Single-Phase Redesign..............................................................................97
21. Calculation Of Secondary Voltage..........................................................102
22. Determing Three-Phase Coil Grouping...................................................106

Appendix
Table A: Parallel Circuits For Two Winding Motors.............................113
Table B: Two-Speed, One Winding Connections..................................113
Table C: Maximum Rotor Diameters....................................................114
Table D: Approximate Flux Densities...................................................114
Table E: Stator - Rotor Combinations...................................................115
Electrical Apparatus Service Association, Inc. 1990-2014 iii

Table F: Motor Full-Load CurrentsThree-Phase AC Induction
Type, Squirrel Cage And Wound Rotor..................................115
Table G: Full-Load CurrentsThree-Phase Synchronous
Motors - Unity Power Factor..................................................116
Table H: Full-Load CurrentsSingle-Phase Motors............................116
Table I: Circular Mils Per Ampere (Approximate Values)...................117
Table J: Distribution Factor..................................................................117
Table K: Chord Factor...........................................................................118
Table L: Radius Of Retangular Wires...................................................119
Table M: Radius Of Square Wires..........................................................119
Table N: Radius Factor..........................................................................119
Table O: Round Magnet Wire Data.......................................................120
Table P: Coil Grouping Chart...............................................................122
Figures A & B: Core Measurements.......................................................126
Glossary..........................................................................................................128
Symbols Used In Formulas.............................................................................132
iv Electrical Apparatus Service Association, Inc. 1990-2014

Preface
Redesigning electric motors has become an increasingly popular service activ-
ity for motor repair companies in recent years. By changing one or more rat-
ings, service centers often can adapt motors to meet new requirements faster
and more economically than they can obtain new ones.
This manual explains how to make any changes in the ratings of ac electric
motors that are possible within design limitations. Examples of each redesign
are included as a guide for making your own redesigns. Besides mathemati-
cal formulas, the manual provides guidelines on the limitations for each type
of redesign. These guidelines will also help you determine whether a desired
new rating is possible before you strip a motor. Terms are expressed in both
English and metric units.
To assure the greatest accuracy, base your calculations on the original wind-
ing data whenever possible. The original data tells you what was required to
produce the original rating. The formulas discussed in this book explain how
to convert to the desired new rating.
Since flux density calculations result in five- to eight-digit figures, it is best to

perform them with a calculator or a computer. If you plan to purchase a calcu-
lator, we strongly recommend buying one that has a Sin key, a square root
() key and an X2 key.
When working out redesigns that do not require density calculations, be sure
that your calculated turns are as close to a whole number as possible before
you round off. This can be accomplished by changing the circuits, the span
and/or the connection.
EASA members who would like to have someone check their calculations,
or assistance in determining whether or not a specific redesign can be made,
should feel free to write, call or FAX the Engineering Department at EASA
Headquarters. We will help you all we can.
My thanks to EASA Staff Engineer Preben Christensen and the 1989-90

EASA Engineering Committee for the many hours they spent critiquing and
adding to the material in this manual.
David L. Gebhart
EASA Staff Engineer
June 1990
Electrical Apparatus Service Association, Inc. 1990-2014 v

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vi Electrical Apparatus Service Association, Inc. 1990-2014

1 Wire Size Change
Whenever the turns in a coil are changed, the wire size usually changes to
provide the same slot fill. This is true no matter where the coil is to be used,
in a motor, a transformer, a relay or other electrical apparatus.
The formula for calculating the circular mil area per turn of the new winding
is:
T1
CM2 = CM x
1
T2
where:
CM2 = circular mil area per turn of the new winding
CM1 = circular mil area per turn of the original winding
T1 = turns per coil of the original winding
T2 = turns per coil of the new winding
The circular mil area per turn determined in this manner makes the slot fill of
the new winding the same as the original winding, providing the thickness of
the slot and/or wire insulation remains the same. Once you know the circular
mil area for the new winding, you can determine the wire size from TableO
on Page 120. If the product you are rewinding was manufactured in North
America, use the AWG column. For equipment made in other parts of the
world, you may need to use either the Metric column or the SWG column.
Sample T1 = 10 turns per coil, 1-#15 (AWG) wire

Redesign
T2 = 16 turns per coil
From Table O, Page 120, 1-#15 wire (AWG) = 3260 circular mils
10
CM2=3260x =2037 circular mils
16
1-#17 wire (AWG) = 2050 circular mils
Electrical Apparatus Service Association, Inc. 1990-2014 1

Most of the time you will not be able to choose a wire size that will match the
calculated value exactly. You will have to choose a circular mil area either
slightly above or slightly below the calculated value. Which one you should
choose may depend on the tightness of the original winding. If the original
winding was tight, select a wire size slightly smaller than the calculated value.
If it was loose, use a wire size slightly above the calculated value. Filling the
slot with as much wire as possible will not increase the output rating or cause
the current to become high. It will, however, decrease heating and improve
efficiency.
When selecting wire sizes, you may prefer to use a number of small wires in
parallel rather than fewer parallels or a single strand of a large wire because
small wires nest better. That is, with small wires there is less space between
the strands than with larger wires. As a result, it may be easier to insert a
number of small wires that total a given circular mil area than to insert fewer
larger wires with nearly the same circular mil area.
When using a number of wires in hand, it is best to keep the wire size varia-
tion down to one size wherever possible. The reason is that in connecting a
small wire used in parallel with a number of larger wires, the end of the small
wire may burn off before the larger wires are hot enough to make a good con-
nection. In this case, the small wire would be dead, serving no purpose but to
cost your company money.
In the American wire gauge system, the circular mil area of wire is nearly
doubled or cut in half every three sizes. For example, #17 wire has a circular
mil area of about 2050 (see wire size chart on Page 120). Doubling this area
gives 4100 circular mils, or approximately the same area of #14 wire, 4110
circular mils. Cutting the same area in half would yield a circular mil area of
1025, which is very close to the 1020 circular mil area of #20 wire. Any wire
could have been chosen for the example with the same results.
(In Metric wire sizes, the circular mil area is nearly doubled or cut in half ap-
proximately every six sizes, but the conversion is not as accurate as it is with
AWG wire.)
As you can well imagine, this rule of thumb can be helpful in determining a
new wire size if it is desirable to rewind a motor with a smaller wire than the
manufacturer used. If the manufacturer used 1-#11 in the AWG system, it can
be replaced by 2-#14; or going to even smaller wire, with 4-#17.
Manufacturers today are using half-size wires in some designs. You can
replace this wire with two wires in parallel. One wire would be 21/2 sizes
smaller, and the other would be 31/2 sizes smaller. For example, 1-#17.5 can
be replaced by 1-#20 and 1-#21.
2 Electrical Apparatus Service Association, Inc. 1990-2014

Rectangular With rectangular wire, multiply the thickness (vertical dimension) by T1/T2,
Wire unless the thickness of the insulation system changes. The width (horizontal
dimension) will remain the same as long as the strands per layer and/or the
insulation thickness do not change. When insulation thickness changes, the
horizontal dimension will change by twice the insulation thickness change,
while the vertical dimension will change by twice the insulation thickness
change, divided by the number of vertical layers. This is based on keeping the
strands per turn and their arrangement in the coil the same.

Sample Suppose we want to change a motor from
Redesign 2300 volts to 4160 volts. If the original turns
and wire size were five turns of one strand of
.171 x .250 [4.34 x 6.35 mm], the new
turns would be:
5x 4160 = 9 turns per coil

2300
The new thickness (T) changes to:
.171 x 5 = .095 Ground wall

9 insulation W
thickness
[4.34 x 5 = 2.4 mm]

Ground wall
insulation
9 thickness
Before the change in insulation thickness is considered, the new wire would
be .095 x .250 [2.4 x 6.35 mm].
Now assume the ground-wall insulation thickness for 2300 volts to be.025
inches [.635 mm], and for 4160 volts .040 inches [1.02 mm]. This is a
difference of .015 inches [.385 mm]i.e., .040 .025 = .015 inches
[1.02 .635 = .385 mm].
The width (W) of the wire, therefore, will be reduced to .250 (2 x .015) =
.250 .030 = .220 inches [6.35 (2 x .385) = 5.58 mm]. The thickness
(T) will be reduced to .095 (2 x .015/9) = .095 (2 x .0017) = .095
.003 = .092 inches [2.4 (2 x .385/9) = 2.31 mm]. Thus, the new wire
size will be .092 x .220 inches [2.31 x 5.58 mm].

Converting This change is not recommended if voltage exceeds 1000 volts or output rating
Rectangular exceeds 300 hp (225 kW), regardless of the voltage rating.
Wire To
The first step in converting rectangular or square wire into round wire is to
Round Wire determine the square mils in the original wire. This is done by multiplying
the thickness times the width (both in inches) and
subtracting the radius factor. The radius factor, given
in Table1.3, is the square mils lost due to the rounded T
corners. Square mils are converted into circular mils
by multiplying by 1.2732. W
The radius for rectangular wire is given in Table 1.1, and for square wire in
Table 1.2.
Table 1.1
Radius Of Rectangular Wires
Radius For Specific Width (Inches)
Thickness - Inches
.189 - .750 up to .188 incl.
0.688 to 0.439 incl. .094
0.438 to 0.226 incl. .063
0.225 to 0.166 incl .047 .047
0.165 to 0.126 inc. .031 .031
0.125 to 0.073 incl. .031 .016
0.072 to 0.051 incl. Rounded Edge .016
0.050 and under Rounded Edge Rounded Edge
TABLE 1.2 TABLE 1.3

Radius Of Square Wires Radius Factor
Thickness (Inches) Radius (Inches) Radius (Inches) Radius Factor (Sq. Mils)
0.438 to 0.226 incl .062 .012 124
0.225 to 0.166 incl .047 .016 210
0.165 to 0.126 incl .031 .031 838
0.125 to 0.073 incl .016 .047 1886
0.072 to 0.050 incl .012 .063 3353
.094 7544
Tables courtesy of Phelps Dodge Magnet Wire Corp.

The formula for determining the circular mil area for a rectangular or square
wire is:
Circular mils=[(thickness x width)radius factor]x1.2732xwires in multiple
Sample For example, suppose we want to convert a .114 x .177 rectangular wire
Redesign into round wires. The thickness (smallest dimension) is .114, and the width
is .177. From Table 1.1, the radius is .016. From Table 1.3, the radius fac-
tor is 210.
T x W = 114 x 177 = 20178 sq. mils
210 (radius factor)
19968 net square mils
19968 x 1.2732 = 25,423 circular mils

From Table O, Page 120:
#15 wire (AWG) = 3260 circular mils
3260 x 7 = 22820
2580 x 1 = 2580

25400 circular mils
Use 7-#15 and 1-#16 (AWG).
Because of the additional air space between strands, round wire of a given
circular mil area will occupy more room in the slot than rectangular or square
wire having the same circular mil area. Therefore, you may have to reduce
the circular mil area of round wire to fit it into the slot.
Aluminum The resistance per foot of any aluminum AWG wire is nearly equal to the
Wire To resistance per foot of a copper wire two sizes smaller. Although the resistance
differs less than two percent, reducing the wire by two sizes in a piece of ac
Copper
equipment would remove too much of the coil from contact with the core.
Wire This could cause the winding to overheat and fail.
If any reduction is to be made on an ac winding in changing from aluminum

to copper wire, reduce a maximum of one size. For highest efficiency, how-
ever, do not reduce the wire size at all. The size of the wire does not affect the
output of ac equipment. The larger the wire, however, the lower will be the
copper losses, so the apparatus will operate cooler and at a higher efficiency.
Use of a large wire will not cause the apparatus to draw excessive current.

2 Voltage Change
For a voltage change, the turns per coil will vary directly as the change in
voltage.
E2
T2=T1x
E1
where:
T2 = new turns per coil

T1 = original turns per coil
E2 = new rated voltage
E1 = original rated voltage
This formula works well for changing from one low voltage to another in
low-voltage systems (600 volts or less). But if either the original or new volt-
age is in the medium- or high-voltage range (above 600 volts), you must also
take into account the special insulation systems required for each voltage. (In
general, the higher the voltage, the thicker the insulation.) Of course with
medium- and high-voltage applications, form-wound coils are also frequently
present. Thus, when redesigning for a new voltage in such cases, calculate
the new wire size as outlined on Page 3.
Medium A redesign can always be made from a medium or high voltage to a low volt-
age. In a change of this type, the output usually can be increased one rating, if
Or High
necessary, without increasing the temperature rating of the insulation system.
Voltage Since the lower voltage requires less insulation, a larger wire can be inserted
To Low into the slot than would be obtained using the formula on Page 1. That means
Voltage less stator copper losses.
Motors designed for operation on medium- or high-voltage lines also may

operate at lower flux densities than those designed to run on low-voltage lines.
Such motors can be strengthened without over-saturating the core. To change
the horsepower or kW in these cases, see Pages 9 - 13.

Low Difficulties can occur when changing from a low voltage to a medium volt-
Voltage age. More slot area must now be taken up by insulation, leaving less room for
To wire. If the output rating is to remain the same, less wire area means higher
stator copper losses. The temperature rise will therefore increase, necessitat-
Medium
ing an insulation system rated for a higher temperature. If it is not desirable to
Voltage increase the temperature rise, the output rating must be decreased. (Insulation
systems for 2000 volts and higher usually contain mica.)
The major problem in changing from a low voltage to a medium or high volt-
age is coil design. It is strongly recommended that form-wound coils be used
in medium- and high-voltage motors with open stator slots. Round wire can
be used on medium-voltage motors that have semi-closed stator slots, but such
motors must be star connected. Never attempt to use round wire above 2400
volts.
Rated When rewinding a motor designed after the mid-1960s, it is best to redesign
Voltage it for the voltage that will actually be applied. Applying higher than rated
And Line voltage could over-saturate the core, causing the current and temperature to
Voltage rise. No-load current also could be higher than nameplate current, resulting in
Not The nuisance tripping of motor protectors. Applying a lower voltage weakens
Same the motor and could cause it to pull a high current at rated load.
Sample Rating: 1.5 hp, 1800 rpm, 230/460 volts.

Redesign Data: 36 slots and coils, 32 turns per coil, 1 - #20 wire (AWG) 1-8 span, 2
and 1Y connection.
Redesign for 575 volts.

575
T2 = 32 x = 40 turns per coil
460
From Table O on Page 121:
Using the forumla from Page 1:
CM2 = 1020 x 32 = 816 circular mils

40
The span does not change.

Since 460 volts were used as the original voltage, the connection will be the
same as the original 460-volt connection (1Y). The new winding data is 40
turns per coil, 1-#21 wire (AWG), 1-8 span, 1Y connection.
If the new turns do not calculate to be close to a whole number, the circuits,
span and/or connection will also have to be changed. See Pages 20 - 22,
23-26, and 27 - 28.

3 Horsepower Or Kilowatt Change
(Power Rating)
For a horsepower or kilowatt change, the turns per coil vary inversely as the
square root of the horsepowers or kilowatts.
T2 = T1 x or T1 x

where:
hp1 = original horsepower
kW1 = original kilowatts
hp2 = new horsepower
kW2 = new kilowatts
Be sure to stay with either hp or kW and do not mix theme.g.,

1hp = .746 kW, or 1kW = 1.34 hp.
Whenever the power rating of a motor is increased, with the number of poles
remaining the same, the core loss will increase. This is because the iron must
be worked harder (at higher flux densities) to produce the added output. In
such cases, the full-load current also will increase more than it is possible to
compensate for by increasing the cross-sectional area of the wire. Thus, the
stator copper loss will increase.
The rotor copper loss is also greater if the power rating of a motor is increased
and the number of poles remain the same, because a higher current now passes
through the bars and end rings. As a result, an insulation system with a
higher temperature rating will be needed. Finally, magnetizing (no-load) cur-
rents also will be higher, and electrical noise will increase.
How much can the power be increased, and what should be the temperature
rating of the new insulation system? The answer to these questions will
depend on the temperature rating of the original insulation system and the
magnetic densities.

Pre-1960 First lets discuss the motors manufactured prior to 1960. In the U.S. and
Motors Canada, this includes U frame and earlier motors that have a Class A insula-
tion system. The horsepower of these motors usually can be increased to the
next highest NEMA standard horsepower rating by redesigning the winding
and using a Class B insulation system.
To determine whether the power can be increased further requires calculation
of the magnetic densities. Refer to the discussion on densities on Pages 42 -
45.
Even if the magnetic densities indicate that you can make an increase electri-
cally, there could be problems from a mechanical standpoint. Too large an
increase in the power rating, for instance, can cause shafts to break and/or
bearings to fail. Such mechanical failures are more likely to occur in the lon-
ger frame length of a given shaft height than in the shorter frame length. For
example, they are more likely to occur in a 256 frame than in a 254 frame, or
in a 200L frame rather than in a 200M frame.
Todays If you are starting with a motor with Class B insulation that was built after the
Motors 1960s (T frame in North America or IEC frames in other parts of the world),
it is difficult to increase the output rating. Never increase it more than one
standard rating, and be sure to use a Class H insulation system. Smaller mo-
tors are operated at such high magnetic densities and with such a high percent-
age of slot fill that uprating them is usually impossible. Caution should be
used if the output power must be increased. Calculate the magnetic densities
as outlined on Pages 42 - 45, and as shown in the example in this chapter.
Effect Of In the past, some service centers thought they could increase the horsepower
Increasing of very old motors by rewinding them using larger wire than the original, or
Wire Size by increasing the temperature rating of the insulation system. This is NOT
true. NEMA and IEC standards specify the starting torque and the maximum
torque motors are to produce according to their rated output power and rpm.
Using larger wire or improving the temperature rating of the insulation will
not increase these torques. Consequently, such measures will not increase the
rated horsepower.
Increasing wire size, however, does reduce the winding loss and temperature
rise under a given load, so the motor can be operated at a higher overload.
(Overload is when a motor operates beyond its rated torque designhp or
kW.)

In the overload condition, the motor will slip more. This causes high current
and higher flux densities, resulting in greater losses and greater heat rise. The
limit to overloading is determined by the pull-out torque of the motor and the
heat limit of the insulation. Increasing the temperature rating of the insulation
system allows the motor to operate at a higher overload. This increases the
service factor, but not the rated output power. (Service factor is the percent
of overload that can be placed on a motor before its operating temperature
exceeds the temperature rating of the insulation system.)
Sample Rating: 50 hp, 1800 rpm, 230/460 volts, 60 hertz.

Redesign Data: 48 slots, and coils, 13 turns per coil, 3-#17 wire (AWG), 1-11, 4 and 2
delta connection.
Core dimensions (inches): bore diameter 9, core length 6.625, tooth width
.312, back iron 1.25.
Redesign for 60 hp.
T2 = 13 x = 11.87 Use 12 turns per coil.

22,500,000 x phase volts x phases x circuits
Flux per pole =
Hertz x turns per coil x coils x DF x CF
22,500,000 x 460 x 3 x 2

=
60 x 12 x 48 x .958 x .966
= 1,941,669 magnetic lines of flux for each pole
Phase volts = line volts for delta connection.
Phase volts = line volts x .58 for star connection.
DF = distribution factor. See Table J, Page 117. (In this example

DF = .958.)
CF = chord factor. See Table K, Page 118. (In this example CF = .966.)
Air-gap area = 3.14 x bore diameter x core length
= 3.14 x 9 x 6.625 = 187 square inches

Tooth area = core length x tooth width x number of teeth x .95
(number of teeth = number of slots)
= 6.625 x .312 x 48 x .95 = 94.3 square inches
Back-iron area = core length x back iron x .95
= 6.625 x 1.25 x .95 = 7.87 square inches

1.57 x flux per pole x poles
Air-gap density =
air-gap area
1.57 x 1,941,669 x 4
=
187
= 65,207 magnetic lines of flux per square inch

Tooth density =
tooth area
1.57 x 1,941,669 x 4
=
94.3

flux per pole
Back-irondensity =
2 x back-iron area
1,941,669
=
2 x 7.87
Maximum Air-gap density: 70,000 magnetic lines of flux per square inch.
Suggested Tooth density and back-iron density: 135,000 magnetic lines of flux per
square inch.
Values

Using the formula from Page 1:
CM = (2050 x 3) x 13 = 6662.5 circular mils

12
The span and connections do not change.
The new winding data is 12 turns per coil, 2-#15 wire (AWG), span 1-11, con-
nected 4 and 2 delta.
span, and/or connection will also have to be changed. See Pages 20 - 22,
23-26, and 27 - 28.

4 Frequency Change
Frequency changes to electrical apparatus are calculated differently, depend-

ing on whether you are making a constant horsepower (kilowatts) or constant
torque change. The difference in the two formulas is illustrated below. For
apparatus other than motors, the constant-torque formula should be used.
Constant Horsepower (kilowatts) Constant Torque
F
T2 = T1 x T2 = T1 x F1
2
where:
F1 = original frequency
F2 = new frequency
When the change is made in the inverse proportion to the frequency change,
as is the case with the constant-torque change, the flux densities remain the
same. If this method is used on a motor, the pound-feet of starting torque and
of maximum torque would remain the same. Output ratings, however, are
based on the percent of starting torque and the percent of maximum torque
that a motor is capable of producing with respect to full-load torque. Thus,
the output rating will change in direct proportion to the frequency change.
The formula for calculating the output power of a motor is:
torque (lb. - ft.)xrpm

hp =
5250
torque (Newton - meters)xrpm

hp =
7120
or
torque (Newton - meters)xrpm
kW =
9550

When frequency changes, the rpm must also change. Thus, if the output
power is to be kept constant, the full-load torque must vary inversely as the
speed changes. In order to be sure that the motor still meets NEMAs or IECs
requirements, the starting torque and maximum torque should be changed
in direct proportion to the change in full-load torque. This is done when the
turns are changed by the square-root method.
50 Hertz A motor can always be changed from 50 hertz to 60 hertz without any difficul-
To ty. Quite often this change can be made without rewinding the motor. When a
60 Hertz 380 volt, 50 hertz motor is operated from a 460 volt, 60 hertz supply, the flux
densities do not change. This is a constant-torque change:
380 x 60 = 456 volts

50
Thus, the motor will operate successfully with an increase in output power of
hp2 = 60 x hp1 = 1.2 x hp1

50
A motor designed to operate on 415 volts, 50 hertz will operate successfully
on 460 volts, 60 hertz with the same rated output. This is a constant-horse-
power change:
415 x = 455 volts
60 Hertz 460 volt, 60 hertz motors can be operated at 415 volts, 50 hertz with the same
To output rating, providing the motor does not become saturated. 460 volt, 60
hertz motors can be operated at 380 volts, 50 hertz with the output rating
50 Hertz
reduced by 50 / 60. That is, a 60 hp or 60 kW output rating would have to be
reduced to 50 hp or 50 kW.
When a motor is changed from 60 to 50 hertz, and its output rating remains
the same, its full-load temperature rise increases. Although an open motor
will not overheat when operated at rated load, it will overheat if it is operated
at service factor load. The service factor should therefore be changed to 1.0.
For a TEFC motor, the temperature rating of the insulation system should be
increased one rating.

25 Hertz A change between 60 or 50 hertz and 25 hertz normally includes a pole
To 60 Or change also in order to keep the speed approximately the same. When chang-
50 Hertz ing from 25 to 60 or 50 hertz, lamination thickness becomes important. Lami-
nation thickness for 60 or 50 hertz motors is approximately .025 inches or
less. Some manufacturers of older motors used a thicker lamination in their
25 hertz motors. If these motors are redesigned for 60 or 50 hertz opera-
tion with normal densities, the core loss and temperature rise will be quite
high. Therefore, their densities should be lower than those shown in Table D
(Page114).
A 25 to 60 or 50 hertz redesign also can result in rotor problems. If the 25

hertz design is for two-pole operation and the 60 or 50 hertz design is for four-
or six-pole operation, the cross-sectional area of the end ring may have to be
cut in half to increase rotor resistance. Sometimes, however, this is not pos-
sible. If rotor resistance is too low, the motor will draw high starting currents
and will have very low starting torque. The more poles a motor has the less
effect the end rings will have on its performance.
If there is to be a large increase in speed, compare the rotor diameter with

those in Table C (Page 114).
Sample Rating: 25 hp, 1500 rpm, 220/380 volts, 50 hertz.

Redesign Data: 60 slots and coils, 12 turns per coil, 2-#16 wires (AWG), 1-13 span, 2
delta-star.

Redesign for 60 hertz, 220 volts.

T2 = 12 x = 11 turns per coil

CM2 = (2 x 2580) x 12 = 5629 circular mills

11


(2 x 1290) + (3 x 1020) = 5640 circular mils

Use 2 - #19 and 3 - #20 wires (AWG).

The span and connection do not change.

New data: 11 turns per coil, 2-#19 and 3-#20 wire (AWG), span 1-13, 2 delta
connection.

If the turns per coil do not calculate to be close to a whole number, it also will
be necessary to change to circuits, span and/or connection. See Pages 20 - 22,
23-26, and 27 - 28.

5 Phase Change
The following formula can only be used when redesigning between two
andthree phases. It cannot be used to change a single-phase motor into a
three-phase motor. To make that type of conversion, follow the example in
Chaper17, Developing A Winding For A Bare Core (Page 85).
The formula for changing a two-phase motor to a three-phase motor is:

T3 = .82 x T2
where:
T3 = turns per coil for a three-phase motor in a star configuration

T2 = turns per coil for a two-phase motor
To change a three-phase motor to a two-phase motor:
T2 = 1.22 x T3 where T3 is in the star configuration

or
T2 = .707 x T3 where T3 is in the delta configuration
Two-phase motors can be converted into three-phase motors without rewind-

ing if approximately 13 percent of the turns can be cut out of B phase.
The cut out coils should be distributed as equally as possible among the B
phase coil groups. One end of B phase is connected to the mid-point of
A phase. The other end of B phase and both ends of A phase are con-
nected to the power source. This connection is called the Scott T. Since
the number of coil groups depends upon the number of phases and the number
of poles, and the coils per group depends upon the number of groups and the
number of slots, both have different values when a phase change is made by
rewinding.
Groups = phasexpoles
coils
Coils per group =
groups
Sample Rating: 20 hp, 1200 rpm, 230/460 volts, 2 phase.

Redesign Data: 72 slots and coils, 22 turns per coil, 1-#16 wire (AWG), 1-10 span, con-
nected for 6 and 3 circuits, 12 groups of 6 coils.

Redesign for three-phase operation.

T3 = .82 x 22 = 18 turns per coil

Groups = 3 x 6 = 18
Coilspergroup = 72 = 4
18
The span remains 1-10.

Since this formula gives turns for a star connection and the original design
was 6 and 3 circuit, the three-phase connection is 6 and 3Y.


CM2=2580x 22 =3153 circular mils

18
3-#20 wires (AWG) = 1020 x 3 = 3060 circular mils
New data: 18 turns per coil, 3-#20 wires (AWG), 1-10 span, connected 6 and
3Y, 18 groups of 4 coils.
span and/or connection will also have to be changed. See Pages 20 - 22,
23-26, and 27 - 28.

6 Circuit Change
When the turns per coil of a redesign do not calculate to be a whole number,
the fractional part of a turn may be eliminated by changing the number of
parallel circuits. The formula is:
N2
T2=T1x N
1
where:
T1 = calculated or original turns per coil
N2 = new number of circuits
N1 = original number of circuits
There are limits to the number of parallel circuits that can be used:
1. The number of circuits cannot be more than the number of poles. (Under
certain conditions it is possible to have a four-circuit connection on a two-
pole motor.)
2. The number of poles must be equal to or be a multiple of the number of

circuits.
3. Odd grouping limits the number of circuits. There must be the same num-
ber of coils in each leg of the parallel circuit. See the Coil Grouping Chart
on Pages 122-123. For a more in-depth discussion of odd grouping, refer
to Page 48.
4. The volts per coil of a mush-wound coil should not exceed 40, if possible
(cf. EASA Technical Manual, Voltage Stresses in Three-Phase, AC Mo-
tors). If a strand from the first turn and a strand from the last turn come
in contact with one another and the volts per coil are too high, a blown
coil could result. On occasion, the volts per coil can be higher. Caution is
advised in selecting materials and in handling the wire. (A mush coil is a
coil made of round wire.)
phase voltage
Volts per coil =
number of coils in series

If the original design of a motor has few turns and a large wire size or many
wires in hand, it may be easier to rewind if the number of parallel circuits is
increased. Doubling the circuits, for example, doubles the turns per coil and
cuts in half the wire size or the number of wires in hand. Of course, doubling
the circuits also doubles the volts per coil.
Sample First make a horsepower change (see Pages 9 - 13).

Redesign Rating: 20 hp, 1200 rpm, 230/460 volts.
Data: 54 slots and coils, 14 turns per coil, 1-#14 and 1-#15 wire (AWG), span
1-8, 2 and 1 delta connection.
Change to 25 hp, 460 volts only:
T2=T1x = 14 x = 12.5 turns per coil
If the 460-volt connection is changed to 2 delta from 1 delta:
T2=12.5 x 2 = 25 turns per coil

1
If the voltage were to remain 230/460 volts, the redesign could not be made in
this manner. To do so would have made a 2 and 4 delta connection. Since 6 is
not a multiple of 4 (Rule 2 above), a four-circuit connection cannot be used on
a six-pole motor.
Voltspercoil = 460 = 51 volts per coil

9



The circular mil area of 1-#14 and 1-#15 is 7370 circular mils.

CM2=7370x 14 =4127 circular mils

25
The span remains the same.
The new data is 25 turns per coil, 1-#14 wire (AWG), span 1-8, connected
2 delta.
At times it may be necessary to change the span and/or connection as well as

the circuits to get the turns to be a whole number. See Pages 23-26 and 27 -
28.

7 Span Or Chord Factor Change
Another method of eliminating a fractional part of a turn when making a rede-

sign is to change the span. This results in a new chord factor. The formula is :
CF1
T2 = T1 x CF
2
where:
T1 = calculated or original turns per coil
CF1 = original chord factor
CF2 = new chord factor
Chord factor is the ratio of the effective turns of a coil to the actual turns.
Effective turns equal actual turns times chord factor. Table 7.1 is a table of
chord factors.
For electrical design considerations, the ideal span would have a chord factor
of .966. This is because a span with a chord factor of .966 is the most ef-
fective in eliminating the adverse effects of harmonics that are present in all
motors and generators. Unfortunately, the ideal span is not always possible to
achieve. It is physically impossible, for instance, to have a span with a .966
chord factor on a 36-slot, four-pole motor. With motors having four or more
poles, the best results are obtained if the chord factor is kept between .900 and
.996. On two-pole motors, however, such a high chord factor would make
winding very difficult, because the coil span would be almost halfway around
the stator. Therefore, for two-pole motors, the span should be shortened until
the chord factor is between .707 and .866.
Chorded A chorded or fractional pitch winding should be used whenever possible. It

Windings makes for shorter end turns, thus reducing the possibility of their interfering
with the end bell during assembly of the motor. It also reduces the magnitude
of air gap harmonics and decreases leakage reactance, thereby improving per-
formance. The span of a chorded winding is always shorter than the span of a
full-pitch winding. The chord factor for a full-pitch winding is 1.0.

Table 7.1
Chord Factor
SLOTS PER POLE
Coil
Span 24 22 20 18 16 15 12 11 10 9 8 6 4 3
1-25 1.000 .990 .951 .866

1-24 .998 .997 .972 .906
1-23 .991 1.000 .988 .940 .831
1-22 .981 .997 .997 .966 .882
1-21 .966 .990 1.000 .985 .924 .866
1-20 .947 .977 .997 .996 .957 .914
1-19 .924 .959 .988 1.000 .981 .951
1-18 .897 .937 .972 .996 .995 .978 .793
1-17 .866 .910 .951 .985 1.000 .995 .863 .756
1-16 .831 .878 .924 .966 .995 1.000 .924 .841 .707
1-15 .793 .841 .891 .940 .981 .995 .966 .910 .809 .643
1-14 .752 .801 .853 .906 .957 .978 .991 .960 .891 .766
1-13 .707 .756 .809 .866 .924 .951 1.000 .990 .951 .866 .707
1-12 .707 .760 .819 .882 .914 .991 1.000 .988 .940 .831
1-11 .707 .766 .831 .866 .966 .990 1.000 .985 .924
1-10 .707 .743 .809 .924 .960 .988 1.000 .981 .707
1- 9 .643 .707 .743 .866 .910 .951 .985 1.000 .866
1- 8 .634 .669 .793 .841 .891 .940 .981 .966
1- 7 .556 .588 .707 .756 .809 .866 .924 1.000 .707
1- 6 .500 .609 .655 .707 .766 .831 .966 .924
1- 5 .588 .643 .707 .866 1.000 .866
1- 4 .556 .707 .924 1.000
1- 3 .707 .866
Chord factor=Sin 90x( teeth spanned

) For a 36-slot, four-pole motor with a 1-8 span:
( ) = Sin70 =.940
slots/pole
Chordfactor=Sin 90x 7
36/4
For a coil span of 1-8, teeth spanned = 7.

The only time it is not advisable to use a chorded winding is when there is
only one slot per pole per phase, such as with a 36-slot, 12-pole winding.
Since in this case the highest chord factor possible with a chorded winding is
.866, it would be best to use a full-pitch winding (span 1-4).
Making a turn change in a motor redesign sometimes causes the densities

to exceed those recommended. In such cases, changing the span to a higher
chord factor occasionally will bring the densities back into an acceptable de-
sign range. The span can also be changed to a lower chord factor to increase
densities when slightly more torque is needed.
Calculating If the slots per pole are not listed in Table 7.1, you can calculate the chord fac-
Chord tor with the formula shown beneath the table. If a sine table is not available or
Factors you do not have a Sin key on your calculator, the chord factor may
be found mathematically by equating the teeth spanned
slots per pole
of your motor with
the teeth spanned
slots per pole
of another motor that is in the table. For example, if you
have a 36-slot, eight-pole motor with a 1-5 span, teeth spanned
slots per pole
=
4 = 4 .
36/8 4.5
If numerator and denominator are multiplied by two to clear the denominator

of fractions, teeth spanned
slots per pole
= 4 x 2 = 8 . Thus, a coil with a 1-5 span and
4.5 x 2 9
4.5 slots per pole would have the same chord factor (.985) as a coil with a 1-9
span and 9 slots per pole.
Sample Start with a horsepower change (see Pages 9 - 13).

Redesign
Rating: 20 hp, 1200 rpm, 230/460 volts.
Data: 54 slots and coils, 14 turns per coil, 1-#14 and 1-#15 wire (AWG), 1-8
span, 2 and 1 delta connection, chord factor = .94.
Change to 25 hp, 230/460 volts.
For the horsepower change:
T2 = T1 x = 14 x = 12.5 turns per coil

The span could be changed to 1-7 or 1-9. From Table 7.1, a 1-7 span has a
chord factor of .866, and a 1-9 span has a chord factor of .985. Since .985 is
within the recommended range for chord factors and .866 is not, change to a
1-9 span.
T2 = 12.5 x .940 = 11.95 turns per coil

.985
Use 12 turns per coil.

Therefore, the circular mil area of 1-#14 and 1-#15 is 7370 circular mils.

12
3260 + (2 x 2580) = 8420 circular mils
Use 1-#15 and 2-#16 wires (AWG).

The connection remains the same.
The new winding data is 12 turns per coil, 1-#15 and 2-#16 wires (AWG), 1-9
span, connected 2 and 1 delta.
At times, it may be necessary to change the circuits and/or connection, as

well as the span, to get the turns to be a whole number. See Pages 20 - 22 and
27 - 28.

8 Winding Connection Change
A third method of eliminating a fractional part of a turn when making a rede-

sign is to change the type of connection. That is, change a star to a delta or a
delta to a star. The two formulas are given below.
Star To Delta Delta To Star

Td = 1.73 x Ty Ty = .58 x Td
where:
Ty = turns per coil - star connection (also called wye or Y connection)
Td = turns per coil - delta connection
A star connection should be used wherever possible. Not only do star con-
nections require fewer turns (and therefore less coil winding time), but they
also eliminate the possibility of a third harmonic or triple frequency current
being present. (These currents sometimes occur in delta-connected motors,
circulating within the delta.) On large, low-voltage motors delta connections
are often used because they require more turns, which enables the designer to
arrive at more accurate calculations.
Whenever you change the connection on a nine-lead motor to eliminate the

fractional part of a turn, be sure to change the connection plate. Motors fail
rapidly when connected externally for the wrong connection.
Sample Start with a horsepower change (see Pages 9 - 13) .

Data: 60 slots and coils, 10 turns per coil, 4-#15 wire (AWG), 1-11 span, con-
nected 4 and 2 star.
Redesign for 40 hp.
T2 = T1 x = 10 x = 8.66 turns per coil
Change the connection from star to delta.
Td = 1.73 x 8.66 = 15 turns per coil

The span and the circuits remain the same.
#15 wire (AWG) = 3260 circular mils. 4 x 3260 = 13040 circular mils

10
CM2 = 13040 x = 8693 circular mils
15
The circular mil area of #16 wire (AWG) is 2580; #17 wire (AWG) has a cir-
cular mil area of 2050.
2580 + (3 x 2050) = 8730 circular mils
The new data is 15 turns per coil, 1-#16 and 3-#17 wires (AWG), span 1-11,
connected 4 and 2 delta.
At times, it may also be necessary to change the circuits and/or span to get the
turns to be a whole number. See Pages 20 - 22 and 23 - 26.

9 The Master Formula
Quite often it is necessary to make more than one change to a motor or gen-
erator. Except for changes from concentric windings to lap windings (which
must be done first), all changes should be worked simultaneously. To do so,
use the following Master Formula, which incorporates all formulas previ-
ously discussed (except the one for phase changes), plus the formula for pole
changing.
E2 CF1 N2
T2 = T1 x x x x E1 x CF2 x N1 xCC
or
where:
T = turns per coil E = voltage (line to line)
hp = horsepower CF = chord factor
kW = kilowatts N = circuits
F = frequency CC = 1.73 if changing star to delta
P = poles CC = .58 if changing delta to star
subscript 1 = original CC = 1.0 if no connection change
subscript 2 = new
A change in the distribution factor also affects the calculated turns, but its ef-
fect is so small that we have ignored it in the Master Formula.
When working with this formula, first calculate T2 using only the known
changes. If the result is not a whole number of turns, or close to a whole num-
ber, other changes can be made. See the example at the end of this chapter.
When a change in the number of poles is to be made, the calculation of turns

using the Master Formula is only the beginning. Pole changing always re-
quires a calculation of the densities. Since densities must be calculated, T2
need not be a whole number but may be rounded off to the nearest whole
number.

Sample Rating: 100 hp, 2300 volts, 4 pole, 25 hertz.
Redesign Data: 72 slots and coils, 13 turns per coil, 1-15 span, 1Y connection.
Redesign for 200 hp, 460 volts, 4 pole, 60 hertz.
Horsepower, frequency and voltage are the known changes. The poles will
not change. At this time it is not known whether the chord factor, circuits or
type of connection will change. Considering only the known changes at this
time:
E2
T2 = T1x x x E
1
T2 = 13 x x x 460 = 1.19 turns per coil

2300
It is evident that other changes (chord factor, circuits, type of connection) also
will have to be made. Other changes that can be made should be considered
and calculated one at a time. In comparison with the other two methods,
changing the span (chord factor) will result in a very small change in the num-
ber of turns. Because changing the span at this time would not do much good,
either a circuit change or a change to a delta connection should be made.
If a change to a delta connection were made:
T2 = 1.19 x CC
T2 = 1.19 x 1.73 = 2.06 turns per coil
Changing to two circuits:

N2
T2 = 2.06 x
N1
T2 = 2.06 x 2 = 4.12 turns per coil

1
Since the fractional part of a turn here is less than 1/2, the span should in-
crease so that the calculated turns decrease. The chord factor for a 1-15 span
= .94. Increasing the span to 1-16 makes the chord factor .966, which is
within the recommended range (see Table K, Chord Factor, Page 118).

CF1
T2 = 4.12 x
CF2
T2 = 4.12 x .94 = 4.0 turns per coil

.966
New data: 4 turns per coil, 1-16 span, 2 delta connection.
The wire size would also change, along with coil insulation.
This example was used because every change except a phase change and pole
change could be worked into it. Because of the large change in speed due to
the frequency change, it is highly unlikely that such a redesign would be made
in the field without changing poles.

10 Converting Concentric Windings
To Lap Windings
A concentric winding is one in which each coil in the group has a different
span (1-8, 1-10, and so forth). The coils of the group thus lay concentrically
(one within another).
A lap winding is one in which all coils in the group have the same span. Thus,
when placed in a motor they overlap each otherwhich gives us the term lap
winding.
Manufacturers use concentric windings because they can be wound efficiently

by machines. From a repair standpoint, using concentric windings usually
means fewer coils are needed, and therefore less coil winding time is required.
If your winders are familiar with or can learn to handle concentric coils, they
usually can wind stators faster with this method than they could with lap
windings. If your winders have difficulty in working with concentric coils, it
is best to convert concentric windings to lap windings.
To make the conversion properly, first determine the effective turns per pole.
To do so, multiply the turns in each coil in a group by the chord factor of that
coil, and add the products.
Effective turns per pole = (T1 x CF1) + (T2 x CF2) + (T3 x CF3) + - - -
where:
T1, T2, T3 - - - - = turns in each coil
CF1, CF2, CF3 - - - - = chord factor of each coil
The next step is to determine the effective turns per coil for the lap winding.
To do this, divide the effective turns per pole by the number of coils in each
group of the lap winding.
effective turns per pole

Effective turns per coil =
coils per group in lap winding
A lap winding has a distribution factor. A span must be decided upon in order
to determine the chord factor. The actual turns per coil may now be calculated
by dividing the effective turns per coil by the product of the distribution factor
times the chord factor.

effective turns per coil
Actual turns per coil =
DF x CF
where:
DF = distribution factor
CF = chord factor
Distribution factors and chord factors, are shown in Tables 10.1 and 10.2.
If the original concentric winding was connected for consequent-pole opera-

tion (all groups have the same polarity), the calculated turns are actually the
effective turns for two poles. Therefore, at some point, they must be divided
by two. This is illustrated in Sample Redesign No. 2. If adjacent poles in
the same phase have a different number of coils, the effective turns must be
determined for both poles, added together, and then divided by two to get the
average effective turns per pole. See Sample Redesign No. 3.
Table 10.1
Distribution Factor (DF)
Coils Per Standard Consequent Concentric

Group 3 Phase Pole 3 Phase
1 1.000 1.000 1.0
2 .966 .837 1.0
3 .960 .831 1.0
4 .958 .829 1.0
5 .957 .828 1.0
6 or more .956 .827 1.0
Standard Winding Consequent Pole where:

180
A =
slots per pole
(
A x B
Sin 2 ) (
A x B
Sin
2 )
DF =
slots
DF = B =
poles x phases
A
( )
B x Sin
2
30
( )
2 x B x Sin
B (Always calculate B
for wound poles.)

Table 10.2
Chord Factor
SLOTS PER POLE
Coil
Span 24 22 20 18 16 15 12 11 10 9 8 6 4 3
1-25 1.000 .990 .951 .866

1-24 .998 .997 .972 .906
1-23 .991 1.000 .988 .940 .831
1-22 .981 .997 .997 .966 .882
1-21 .966 .990 1.000 .985 .924 .866
1-20 .947 .977 .997 .996 .957 .914
1-19 .924 .959 .988 1.000 .981 .951
1-18 .897 .937 .972 .996 .995 .978 .793
1-17 .866 .910 .951 .985 1.000 .995 .863 .756
1-16 .831 .878 .924 .966 .995 1.000 .924 .841 .707
1-15 .793 .841 .891 .940 .981 .995 .966 .910 .809 .643
1-14 .752 .801 .853 .906 .957 .978 .991 .960 .891 .766
1-13 .707 .756 .809 .866 .924 .951 1.000 .990 .951 .866 .707
1-12 .707 .760 .819 .882 .914 .991 1.000 .988 .940 .831
1-11 .707 .766 .831 .866 .966 .990 1.000 .985 .924
1-10 .707 .743 .809 .924 .960 .988 1.000 .981 .707
1- 9 .643 .707 .743 .866 .910 .951 .985 1.000 .866
1- 8 .634 .669 .793 .841 .891 .940 .981 .966
1- 7 .556 .588 .707 .756 .809 .866 .924 1.000 .707
1- 6 .500 .609 .655 .707 .766 .831 .966 .924
1- 5 .588 .643 .707 .866 1.000 .866
1- 4 .556 .707 .924 1.000
1- 3 .707 .866

( ) = Sin70 =.940
slots/pole
36/4

Sample Both windings connected in the standard manner.
No. 1
Data: 36 slots, 24 coils, 40 - 80 turns per coil, 1-#23 wire (AWG), spans of
1-7 and 1-9, connected 2 and 1Y; chord factors .866 for 1-7 span, .985 for 1-9
span.
Redesign to a lap winding.
Effective turns per pole:
40 x .866 = 34.64
80 x .985 = 78.8
113.44 effective turns per pole
In the lap winding, there will be three coils per group.
Effective turns per coil = 113.44 = 37.81 effective turns per coil
3
From Table 10.1, the distribution factor is .960. If a 1-8 span is chosen, the
chord factor is .940 (Table 10.2).
37.81
Actual turns per coil = = 42 turns per coil
.960 x .940
If a span of 1-9 is chosen, the chord factor is .985.

37.81
.960 x .985
Since the small coil on the original winding had 40 turns, we know 40 turns
of 1-#23 wire (AWG) can be used in the lap winding. A 1-8 span, though, is
slightly better than a 1-9 span. If the slot can hold four additional strands (two
per coil side) of #23 wire (AWG), the new winding should be 42 turns per
coil, 1-#23 wire (AWG), span 1-8, connected 2 and 1Y. On the other hand, if
the wire size must be reduced to accommodate the additional turns, it would
be best to use 40 turns per coil, 1-#23 wire (AWG), span 1-9, connected 2 and
1Y.
Sample Concentric winding connected consequent pole. Lap winding connected in

Redesign standard manner.
No. 2 Rating: 1 hp, 1800 rpm, 230/460 volts.
Data: 36 slots, 18 coils, 77 turns per coil, 1-#22 wire (AWG), span of 1-8,
1-10, 1-12, connected 2 and 1Y. Chord factors are .94, 1.0, and .94,
respectively.

This redesign is calculated in the same manner as Sample Redesign No. 1,

except that it will be necessary to divide by two, because we will be calculat-
ing effective turns for two poles. This can be done in the first, second or third
step. In this example it will be done in the second step.
Effective turns for two poles:
77 x .940 = 72.38
77 x 1.0 = 77.0
77 x .940 = 72.38
221.76 effective turns for two poles
Since the lap winding will have three coils per group and the effective turns
we calculated were for two poles, we divide by 3 x 2:
Effective turns per coil = 221.76 = 36.96 effective turns per coil
3x2
The distribution factor is .960 (Table 10.1). If a 1-8 span is chosen, the chord
factor is .940 (Table 10.2).
Actual turns per coil = 36.97 = 41 turns per coil

.960 x .940
If a 1-9 span is chosen, the chord factor is .985.
Actual turns per coil = 36.97 = 39 turns per coil

.960 x .985
Since a lap winding requires the use of a coil separator, it may be necessary
to reduce the wire size to 1-#25 and 1-#26 wire (AWG), regardless of which
turns and span combination is used. 41 turns, span 1-8 is preferred, but if this
requires a reduction in wire size when 39 turns would not, use 39 turns, span
1-9. In either case, the connection should be 2 and 1Y.
Sample Both windings connected in the standard manner. Concentric winding has
Redesign six groups of two coils and six groups of one coil. Lap winding will have 12
groups of three coils.
No. 3
Rating: 3 hp, 1800 rpm, 230/460 volts.
Data: 36 slots, 18 coils, 45 turns per coil, 1-#19 wire (AWG), spans for two
coils/group are 1-8 and 1-10 (chord factors = .94 and 1.0), span for one coil/
group is 1-8 (chord factor = .94), connected 2 and 1Y.

Effective turns per pole:
First Group Second Group

45 x .940 = 42.3 45 x .940 = 42.3
45 x 1.0 = 45.0
87.3
Effective turns for 2 poles=87.3 + 42.3=129.6 effective turns for 2 poles
Average effective turns per pole= 129.6 = 64.8 average effective turns per pole
2
In the lap winding there will be three coils per group.
64.8
Effective turns per coil = = 21.6 effective turns per coil
3
The distribution factor is .960 (Table 10.1). Using a 1-8 span, the chord factor
is .940 (Table 10.2).
21.6
Actual turns per coil= .96 x .94 = 23.9 Use 24 turns per coil.
Using a 1-9 span:

21.6
Actual turns per coil= = 22.8 Use 23 turns per coil.
.96 x .985
Since a coil separator will be needed with the lap winding and there will be
three more turns per slot with the 1-8 span (48 versus 45), the wire size may
have to be reduced to 1-#22 and 1-#23 wire (AWG). With only one more turn
per slot using the 1-9 span, it still may be possible to use 1-#19 wire (AWG).
In either case, the connection will remain 2 and 1Y.

11 Converting Lap Windings To
Concentric Windings
As indicated in the previous chapter, a lap winding is one in which all coils
in the group have the same span, so that when placed in a motor, they overlap
each other. A concentric winding, on the other hand, is one in which each coil
in the group has a different span (1-8, 1-10, and so forth). The coils of the
group thus lay concentrically (one within another).
In order to repair small motors more economically many service centers rou-
tinely convert lap windings to concentric windings. By doing so, they save a
great deal of time because they usually need to wind only about half as many
coils. Winders who are adept at handling concentric coils can also wind a sta-
tor more quickly with this approach than with a lap winding.
One drawback of concentric windings is that they are not as efficient as lap
windings, due to losses in the end turns and harmonics in the iron. With small
motors, which usually run cooler than their rated temperature rise, a slight loss
in efficiency will not cause them to overheat. But medium and large motors
(20 hp and up) that were originally designed with lap windings should not
be converted to concentric unless the application can stand a motor with a
higher temperature rise. Redesigns of this type require the use of an insulation
system with a temperature rating one classification higher than the original
system.
To change a lap winding to a concentric winding, the first step is to convert

the actual turns per coil into effective turns per coil. This is done by multiply-
ing the turns times the distribution factor times the chord factor.
Effective turns per coil = actual turns per coil x DF x CF

where:
DF = distribution factor
CF = chord factor
Next, multiply the effective turns per coil by the number of coils in each group
of the lap winding and by two to obtain the effective turns for two poles of the
concentric winding. This cuts the total number of coils in half.
Effective turns for two poles = effective turns per coil x coils per group x 2

The coils of the concentric winding will have the same number of turns and
will be connected for consequent-pole operation. There will be only half as
many groups as were in the lap winding. Therefore, there will be as many
coils with a span longer than full pitch as there are coils having a span less
than full pitch. With an odd number of coils per group, the span of the middle
coil will be such that chord factor is 1.0 (full pitch). The actual turns per coil
are calculated by dividing the effective turns for two poles by the sum of all
the chord factors of the coils in the concentric group.
effective turns for two poles
Actual turns per coil =
CF1 + CF2 + CF3 + - - -
where:
CF1, CF2, CF3 + - - - = chord factors of the individual coils in the concentric winding.
Sample Rating: 1 hp, 1800 rpm, 230/460 volts.

Redesign Data: 36 slots and coils, 41 turns per coil, 1-#22 wire (AWG), span 1-8, con-
nected 2 and 1Y.
Redesign to a concentric winding.
From Table 11.1, the distribution factor is .960.
Table 11.1

1 1.000 1.000 1.0
2 .966 .837 1.0
3 .960 .831 1.0
4 .958 .829 1.0
5 .957 .828 1.0
6 or more .956 .827 1.0

180
A =
slots per pole
(
A x B
Sin 2 ) (
A x B
Sin
2 )
DF =
slots
DF = B =
poles x phases
A
B x Sin
2
( ) 30
( )
2 x B x Sin
for wound poles.)

From Table 11.2, the chord factor is .940.
Effective turns per coil = 41 x .960 x .940 = 37.0 effective turns per coil
Effective turns for two poles = 37 x 3 x 2 = 222 effective turns for two poles
Table 11.2
Chord Factor
SLOTS PER POLE
Coil
Span 24 22 20 18 16 15 12 11 10 9 8 6 4 3
1-25 1.000 .990 .951 .866

1-24 .998 .997 .972 .906
1-23 .991 1.000 .988 .940 .831
1-22 .981 .997 .997 .966 .882
1-21 .966 .990 1.000 .985 .924 .866
1-20 .947 .977 .997 .996 .957 .914
1-19 .924 .959 .988 1.000 .981 .951
1-18 .897 .937 .972 .996 .995 .978 .793
1-17 .866 .910 .951 .985 1.000 .995 .863 .756
1-16 .831 .878 .924 .966 .995 1.000 .924 .841 .707
1-15 .793 .841 .891 .940 .981 .995 .966 .910 .809 .643
1-14 .752 .801 .853 .906 .957 .978 .991 .960 .891 .766
1-13 .707 .756 .809 .866 .924 .951 1.000 .990 .951 .866 .707
1-12 .707 .760 .819 .882 .914 .991 1.000 .988 .940 .831
1-11 .707 .766 .831 .866 .966 .990 1.000 .985 .924
1-10 .707 .743 .809 .924 .960 .988 1.000 .981 .707
1- 9 .643 .707 .743 .866 .910 .951 .985 1.000 .866
1- 8 .634 .669 .793 .841 .891 .940 .981 .966
1- 7 .556 .588 .707 .756 .809 .866 .924 1.000 .707
1- 6 .500 .609 .655 .707 .766 .831 .966 .924
1- 5 .588 .643 .707 .866 1.000 .866
1- 4 .556 .707 .924 1.000
1- 3 .707 .866

( ) = Sin70 =.940
slots/pole
36/4

There will be six groups of three coils in the new concentric winding. The
three spans for a four-pole, 36-slot motor must be 1-8, 1-10 and 1-12. The
chord factors are .940, 1.0 and .940 (Table 11.2).
222
.940 + 1.0 .940
Since there are fewer turns per slot than there were in the lap winding, the
wire size will remain the same.
New data: 36 slots, 18 coils, 77 turns per coil, 1-#22 wire (AWG), spans of
1-8, 1-10 and 1-12, connected 2 and 1Y.

12 Notes On Pole Changing
(Densities)
Whenever a redesign is made for a change in the number of poles, it is strong-

ly recommended that the densities in the tooth, back iron and air gap be calcu-
lated. Table 12.1 gives suggested values that should keep the temperature rise
within the limits of a Class B insulation system for todays motors, and within
the limits of a Class A insulation system for pre-1960 motors. Older motors
and energy-efficient motors are designed toward the pre-1960 values, while
the newer standard motors are designed toward todays values. These values
are for continuous-duty motors. For a 30-minute duty motor, the densities can
be increased approximately 22 percent.
Table 12.1
Approximate Flux Densities - Lines Per Square Inch*
Frame Type Air Gap Tooth Back Iron

2 Poles 4 Poles 6 Poles 8 Poles
Todays 60 Hertz Motors 46,000 55,000 54,000 54,000 120,000 115,000
Todays 50 Hertz 50 Motors 48,300 57,700 56,700 56,700 126,000 121,000
Pre-1960 Semi-closed Stator Slots 39,000 47,000 47,000 48,000 100,000 95,000
Pre-1960 Open Stator Slots 36,000 40,000 39,000 38,000 85,000 75,000
Approximate Flux Densities - Lines Per Square Centimeter*

Pre-1960 motors - Class A temperature rise; today;s motors - Class B temperature rise.
* 1 Tesla = 64,500 lines per square inch = 10,000 Gauss = 1 Weber per square meter = 10,000 lines per square
centimeter.
Higher densities can be used with a high-temperature insulation system if the

application can stand a motor with a higher temperature rise. If the motor was
originally designed with a Class B insulation system, the values in Table 12.1

can be increased 10 percent if a Class F insulation system is used, and 20
percent if a Class H system is used. If the motor was originally designed with
a Class A insulation system, the maximum suggested densities for use with a
Class B insulation system would be 15 percent above the values in Table 12.1.
Twenty-five percent is the maximum suggested increase with a Class F system
and 35 percent with a Class H system.
When a pole change is made, however, both the tooth and back-iron densities
will not be close to the value shown in the table. An increase in poles will
cause the back-iron density to decrease, while a decrease in poles will cause
the back-iron density to increase. The latter may result in a low tooth den-
sity. Base your insulation system on the tooth or back-iron density that is the
highest.
Important Five core dimensions are needed to calculate the air-gap, tooth and back-iron
Information densities: 1) bore diameter; 2) core length; 3) number and width of air vents;
For Taking 4) depth of stator back iron; and 5) stator tooth width. Figure 12.1 illustrates
these dimensions.
Measurements
Figure 12.1
Frame Shell
A.
Back Iron
Outer Perimeter Of
Stator Lamination
1/2 Tooth Length
Average Tooth Width 1/2 Tooth Length

(measure with micrometer
or vernier caliper)
Bore Diameter
(inside diameter)
B. Gross Core Length
Finger
Plate
Finger Plate Air Duct Width Lamination
Stator Core

The bore diameter is the inside diameter of the stator corei.e., the distance
from the top of one tooth to the top of the tooth directly across the stator.
The gross core length is the total length of the stator core lamination, includ-
ing the ventilation or air ducts. (The finger plates at the core ends are not
included in this measurement.) To get the net core length (i.e., the active
iron length for tooth and back-iron areas), subtract the distance across all air
vents in the core from the gross length.
The number and width of air ducts, when used, must also be recorded on the
data sheet.
The depth of back iron is the distance from the bottom of the slots to the
outside of the lamination. It does not include the thickness of the frame
shell. If this distance varies, use the shortest dimension. Always measure
the depth of the back iron in thousandths.
The average tooth width is the width of the iron between adjacent slots. It
should be measured about halfway down its length unless the tooth is very
narrow at one point. Accurate measurement of the tooth width is critical in
many redesigns. Consequently, this measurement should always be made
with a micrometer or a vernier calipernever with a tape or ruler!
The formulas for calculating the areas are:
Air-gap area = 3.14 x bore diameter x gross core length
Back-iron area = .95 x net core length x depth of back iron
Tooth area = .95 x net core length x tooth width x no. of teeth
The constant .95 is called the stacking factor. Its purpose is to make allow-
ances for the insulation coating on the laminations. Note that the formulas
for both the tooth area and core area contain the stacking factor and net core
length. Therefore, if you are calculating in longhand, you can save a step by
multiplying these two factors together first.
The density formulas are as follows:

Air-gap density =
air-gap area

flux per pole
Back-iron density =
2 x back-iron area

Tooth density =
tooth area
Note that the numerators of the tooth density and air-gap density formulas
are the same. Multiplying all the figures in the numerator before doing any
dividing can save steps and time no matter what method is used to do the
calculating.
Stator - Table 12.2 lists stator - rotor slot combinations that may cause problems.
Rotor Slot When considering a redesign involving a change in the number of poles,
Combinations subtract the number of rotor slots from the number of stator slots and see if
the difference appears in the table. The plus figures are used when the number
of stator slots exceeds the number of rotor slots. The minus figures are used
where the rotor slots exceed the stator slots.
If the difference appears in the table, consider how it may affect motor perfor-
mance on the desired application. If improper operation could result, do not
make the redesign.
Table 12.2
Stator - Rotor Slot Combinations
POLES A (NOISE) B (COGGING) C (CUSP)
2 1, 2, 3, 4 6, 12, 18, 24 2, -4, -10

4 1, 2, 3, 4, 5, 6 12, 24, 48, 60 4, -8, -20
6 1, 2, 4, 5, 7, 8 18, 36, 54, 72 6, -12, -30
8 1, 2, 6, 7, 9, 10 24, 48, 72 8, -16, -40
10 1, 2, 8, 9, 11, 12 30, 60, 90 10, -20, -50
12 1, 2, 10, 11, 13, 14 36, 72 12, -24, -60
14 1, 2, 12, 13, 15, 16 42 14, -28
16 1, 2, 14, 15, 17, 18 48 16, -32
18 1, 2, 16, 17, 19, 20 54 18, -36
20 1, 2, 18, 19, 21, 22 60 20, -40
24 1, 2, 22, 23, 25, 26 72 24, -48
32 1, 2, 30, 31, 33, 34 96 32, -64
36 1, 2, 34, 35, 37, 38 108 36, -72
48 1, 2, 46, 47, 49, 50 144 48, -96

Column A lists combinations that could produce noise. It shows that if the dif-
ference between stator and rotor slots is one or two, regardless of the number
of poles, noise can be produced. Noise may also be produced if the difference
is one or two from the number of poles. That is, if a motor is to be redesigned
for six-pole operation, noise may be produced if the difference is four, five,
seven or eight. If it is to be redesigned for eight-pole operation, noise could
be produced if the difference is six, seven, nine or ten.
Column B lists the combinations that could produce cogging. This can occur
when the difference between the stator and rotor slots is equal to three times
the number of poles, or a multiple of three times the number of poles. For
a six-pole motor, this would be 18, 36, 54, 72 and so on; for an eight-pole
motor, it would be 24, 48, 72, and so forth.
Figure 12.2
As shown in Figure 12.2, cogging is a variation in the amount of starting

torque the motor is capable of producing, depending on how the stator and
rotor slots line up. Theoretically, the speed-torque curve for all motors should
follow the solid line at all times.
As an example of the effect cogging can have, assume that a motor will
always start fully loaded and that its keyway is pointed straight up. If the
starting torque were measured and found to be 150 percent of full-load torque,
the motor, when energized, would follow the solid line in Figure 12.2 and
accelerate to full-load speed without difficulty. Now assume that the same
motor is stopped with the keyway at the two oclock position. If starting
torque were now measured and found to be 110 percent of full-load torque, the
motor would still accelerate to full-load speed when energized, but would take
longer to reach that speed because the starting torque is less.

Suppose we now bring the motor to rest with the keyway at the four oclock
position and find the starting torque to be only 80 percent of full-load torque.
If the motor were energized in this circumstance, it would not run unless the
load were reduced to less than 80 percent of full load. It is possible for cog-
ging to be so severe that a motor would be unable to start even with no load
attached. (An example of this would be the dead spots that occur when a
wound-rotor motor is energized with the rings shorted.)
Note: The keyway in the above example is used solely to illustrate how
the stator and rotor slots line up with respect to one another. We are not
implying that the maximum and minimum values of starting torque will be
120 mechanical degrees apart.
Column C lists the combinations that can produce a cusp. A cusp can occur
when: 1) the difference between the stator and rotor slots is equal to the
number of poles; or 2) when the number of rotor slots exceeds the number
of stator slots by two times or five times the number of poles. For a six-pole
motor, this is +6, -12 and -30; for an eight-pole motor, it is +8, -16 and -40.
The cusp is illustrated in Figure 12.3.
Figure 12.3
As an example, assume an 1800 rpm motor has a cusp, so its speed-torque

curve follows the dashed line in the illustration. If the motor is started fully
loaded, it will accelerate to 180-200 rpm and continue to run at that speed
until either the load is reduced enough to permit it to accelerate, or the protec-
tors take it off the line. The cusp point can be so severe that the speed-torque
curve will cross the zero-torque line. In such cases, the motor would never be
able to reach running speed even with no load attached.
With an open-slot rotor, the bars can be readily counted. There are two ways
to determine the number of bars in a closed-slot rotor, the best of which is to
put the rotor in a growler and place a sheet of paper over it. Now energize

the growler and sprinkle iron filings on the paper. The filings will then line
up along the bars, allowing you measure the distance between two bars. To
determine the number of bars, simply measure the circumference of the rotor
and divide by the distance between bars.
The second method of determining the number of bars in a closed-slot rotor is

to heat the rotor slightly until there is a discoloration between where there are
bars and where there is solid iron. The bars can be counted, or the distance
between two adjacent bars can be measured and divided into the circumfer-
ence of the rotor.
Odd Quite often when you change the number of poles in a motor, odd grouping
Grouping occurs. Odd grouping means that the number of coils in each group is not the
same.
Odd grouping limits the number of parallel circuits. Each leg of a parallel cir-
cuit must have the same number of coils. If not, the leg with the fewest coils
will carry the most current, causing these coils to become hot and burn.
When odd grouping occurs, the arrangement of the coils may determine the
type of internal connection that must be used. Sometimes it will be necessary
to use the short jumper (1-4), while at other times the long jumper (1-7) must
be used. There also are many instances when either the short jumper or the
long jumper could be used.
The Coil Grouping Chart (Table P, Pages 122 - 123) shows the maximum
number of parallels possible with the grouping as shown. It also indicates
whether or not a short or long jumper must be used.
In some cases, it may be possible to rearrange the grouping for more parallels.
The maximum number of parallels can be determined by dividing the groups
that you have the fewest number of by three. For example, suppose you have
48 slots, 12 poles, 24 groups of one and 12 groups of two. Since there are
fewer groups of two than groups of one, divide 12/3 = 4. The maximum
number of parallels, therefore, would be four.
(The Coil Grouping Chart covers the most frequently used number of stator
slots from two through 24 poles. How grouping is determined is illustrated in
Chapter 22, Pages 106 - 111.)
One of the first things to do when redesigning a motor is to choose the number
of parallel circuits. So be sure to check the grouping before deciding.

13 Decreasing Speed By Increasing Poles
The first step in making a redesign that involves decreasing the speed by
increasing the poles is to check the stator-rotor slot combination with Table
13.1. (See Pages 45 - 48 for an explanation of how to use this table.)
Table 13.1
2 1, 2, 3, 4 6, 12, 18, 24 2, -4, -10

4 1, 2, 3, 4, 5, 6 12, 24, 48, 60 4, -8, -20
6 1, 2, 4, 5, 7, 8 18, 36, 54, 72 6, -12, -30
8 1, 2, 6, 7, 9, 10 24, 48, 72 8, -16, -40
10 1, 2, 8, 9, 11, 12 30, 60, 90 10, -20, -50
12 1, 2, 10, 11, 13, 14 36, 72 12, -24, -60
14 1, 2, 12, 13, 15, 16 42 14, -28
16 1, 2, 14, 15, 17, 18 48 16, -32
18 1, 2, 16, 17, 19, 20 54 18, -36
20 1, 2, 18, 19, 21, 22 60 20, -40
24 1, 2, 22, 23, 25, 26 72 24, -48
32 1, 2, 30, 31, 33, 34 96 32, -64
36 1, 2, 34, 35, 37, 38 108 36, -72
48 1, 2, 46, 47, 49, 50 144 48, -96
The formulas for calculating the power output and synchronous rpm of a
motor are:
T x rpm TM x rpm
hp = hp =
5250 7120
TM x rpm
kW = Syn. rpm = 120 x hertz
9550 poles
where:
T = torque in pound-feet
TM = torque in Newton-meters
rpm = operating speed

Output At a given air-gap density, the full-load torque of a motor will be approxi-
Power mately the same regardless of the number of poles. Thus, as can be seen from
Versus the above formulas, as the rpm is decreased by increasing the poles (with the
torque kept constant), the horsepower will decrease in direct proportion to the
Speed
reduction in speed.
If the motor will be returned to the same application, a constant torque change
should be made. A constant horsepower change (as is usually requested) may
provide more power than is necessary, thus causing the motor to operate at
a lower efficiency. If the speed decrease is small, the motor will operate at
approximately the same temperature rise when fully loaded. But as the motor
slows down, it loses its ability to dissipate heat. Also, the more poles there
are, the lower will be the efficiency of the motor. Thus, the output power may
have to be decreased more than indicated in the above formula if the tempera-
ture is to remain the same.
For a small increase in the number of poles, the output power may be kept
constant if the application can stand a hotter motor and the magnetic densities
permit it. This requires an increase in the temperature rating of the insulation
system. The new temperature rating will depend upon the densities. Refer to
the discussion of density that begins on Page 42.
When the number of poles is to be increased, the tooth density will be the gov-
erning factor. The air-gap density will also be a factor. The back iron, howev-
er, will always decrease. Thus, when increasing poles, be sure to measure the
width of the stator tooth as accurately as possible with a micrometer, because
this dimension is needed to calculate the tooth density.
Connection When using a calculator, determine what type of connection (star or delta),
Choice how many parallel circuits and what span is to be used before beginning the
calculations. These can be adjusted later if necessary.
The choice of parallel circuits can lead to trouble. When the number of poles
is changed, odd grouping frequently occursi.e., all groups do not have the
same number of coils. Since each leg of a parallel circuit must have the same
number of coils, odd grouping limits the number of parallels that can be used.
To determine how many circuits can be used, divide the fewest number of
groups by three. Assume, for example, that you have 60 slots and six poles
with 12 groups of three and six groups of four. The fewest number of groups
is the six groups of four. Dividing six by three equals two, so the maximum
number of parallels is two. (Refer to the Coil Grouping Chart, Table P on
Pages122 - 123.)

The choice of a connection depends on the output rating, the voltage rating,
the number of possible parallel circuits, and the volts per coil (suggested
maximum is 40 volts). A span should be chosen that has a chord factor close
to .966 (see discussion on chord factor, Pages 23 - 26).
Sample Original nameplate data: 75 hp, 1175 rpm, 460 volts, 60 hertz, frame 405T,
Redesign 3phase, TEFC.
Original winding data: 72 coils, 8 turns per coil, 4-#15 wire (AWG), span
1-10, connected 3 star, chord factor = .924 (see Table 13.2).
Core data (in inches): 72 slots, bore 11.5, core length 9, tooth width .285,
back iron 1.187, 57 rotor bars (refer to Figures A and B, Page 124).
Desired new rating: 60 hp, 900 rpm, 460 volts, 60 hertz, 3 phase
Stator-rotor slot combination is okay. Assume a 2 Y connection, 1-8 span
(chord factor = .94; see Table 13.2), grouping - 24 groups of 3; distribution
factor = .96 (see Table 13.3).
phase volts 460 x .58

Volts per coil = = = 22.2 volts
coils in series 12
(Volts per coil should not exceed 40, if possible.)
For a star connection, phase voltage is 58 percent of line voltage (460 x .58).
For a delta connection, phase voltage equals line voltage. An eight-pole mo-
tor connected for two circuits has four groups in series. With three coils per
group there would be 12 coils (4 x 3) in series.
Calculate the turns using the Master Formula (see Page 29).
E2 CF1 N2
460 x .924 x 2 x1.0

= 8 x x x x
460 .94 3
= 6.77 turns per coil

Table 13.2
Chord Factor
SLOTS PER POLE
Coil
Span 24 22 20 18 16 15 12 11 10 9 8 6 4 3
1-25 1.000 .990 .951 .866

1-24 .998 .997 .972 .906
1-23 .991 1.000 .988 .940 .831
1-22 .981 .997 .997 .966 .882
1-21 .966 .990 1.000 .985 .924 .866
1-20 .947 .977 .997 .996 .957 .914
1-19 .924 .959 .988 1.000 .981 .951
1-18 .897 .937 .972 .996 .995 .978 .793
1-17 .866 .910 .951 .985 1.000 .995 .863 .756
1-16 .831 .878 .924 .966 .995 1.000 .924 .841 .707
1-15 .793 .841 .891 .940 .981 .995 .966 .910 .809 .643
1-14 .752 .801 .853 .906 .957 .978 .991 .960 .891 .766
1-13 .707 .756 .809 .866 .924 .951 1.000 .990 .951 .866 .707
1-12 .707 .760 .819 .882 .914 .991 1.000 .988 .940 .831
1-11 .707 .766 .831 .866 .966 .990 1.000 .985 .924
1-10 .707 .743 .809 .924 .960 .988 1.000 .981 .707
1- 9 .643 .707 .743 .866 .910 .951 .985 1.000 .866
1- 8 .634 .669 .793 .841 .891 .940 .981 .966
1- 7 .556 .588 .707 .756 .809 .866 .924 1.000 .707
1- 6 .500 .609 .655 .707 .766 .831 .966 .924
1- 5 .588 .643 .707 .866 1.000 .866
1- 4 .556 .707 .924 1.000
1- 3 .707 .866

( ) = Sin70 =.940
slots/pole
36/4

Table 13.3

1 1.000 1.000 1.0
2 .966 .837 1.0
3 .960 .831 1.0
4 .958 .829 1.0
5 .957 .828 1.0
6 or more .956 .827 1.0

180
A =
slots per pole
(
A x B
Sin 2 ) (
A x B
Sin
2 )
DF =
slots
DF = B =
poles x phases
A
B x Sin
2
( ) 30
( )
2 x B x Sin
for wound poles.)
To make more turns for ease in winding, change to a delta connection (CC
changes from 1.0 to 1.732). But first check the volts per coil.
Volts per coil = 460 = 38.3 volts

12
This is still below our suggested maximum value of 40.
T2 = 6.77 x 1.732 = 11.7 turns per coil
A motor is stronger if you round off downward rather than upward. Select a
span (chord factor) that will reduce the size of the fractional turn and bring it
closer to a whole number. Therefore, change the span to 1-9 (CF = .985).
(See Table 13.2.)
.94
T2 = 11.7 x = 11.2 turns per coil
.985
Use 11 turns.
Calculate densities based on a winding of 11 turns per coil, span 1-9, con-
nected 2 delta for 460 volts.
Flux per pole =
hertz x coils x turns per coil x chord fact. x dist fact.

22,500,000 x 460 x 3 x 2
=
60 x 72 x 11 x .985 x .96
= 1,382,000 magnetic lines of flux per pole
flux per pole 1,382,000

Back-iron density = =
2 x core length x back iron x .95 2 x 9 x 1.187 x .95
1.57 x flux per pole x poles 1.57 x 1,382,000 x 8

Air-gap density = =
3.14 x bore x core length 3.14 x 11.5 x 9
1.57 x flux per pole x poles 1.57 x 1,382,000 x 8

Tooth density = =
core length x slots x tooth width x .95 9 x 72 x .285 x .95
The back-iron density here is low, which will always be the case when you
redesign for more poles. The air-gap and tooth densities, however, are close
to the values given in Table 13.4, so this winding is acceptable. (If you are
attempting a redesign and the densities are too high or too low, refer to Pages
89 - 93.)
To complete the above redesign, we must now calculate the new wire size.
Using the formula from Page1:

T1
CM2 = CM1 x
T2
The circular mil area of #15 wire (AWG) is 3260 (Table O, Page 120).

8 = 9484 circular mils
CM2 = 13040 x
11
3-#17 and 2-#18 wire (AWG) = (3 x 2050) + (2 x 1620) = 9390 circular mils

Table 13.4


centimeter.
For a 60 hp motor operating on 460 volts, the approximate full-load current is

77 amperes. (See Table F, Page 115.)
circular mils x circuits
Circular mils per ampere =
phase amperes
For a delta connection, phase amperes equal 58 percent of line amperes. For a
star connection, phase amperes equal line amperes.
Circular mils per ampere = 9390 x 2 = 420 circular mils per ampere
.58 x 77
The calculated wire is large enough to carry the full-load amperes of this
motor.
The new winding data therefore will be 11 turns per coil, 3-#17 and 2-#18
wire (AWG), span 1-9, connected 2 delta.

Table 13.5
Circular Mils Per Ampere (Approximate Values)
Frame Open-Drip Proof Totally Enclosed
Pre-1960 Motors 430 550

Present Day Motors 330 450
Note: Pre-1960 - Class A insulation; present day - Class B
insulation. Values could be lower with Class F or H insulation.

14 Increasing Speed By
Decreasing Poles
A redesign involving a decrease in the number of poles will result in an in-

crease in the speed of the motor. There are, however, practical limitations on
how much the speed may safely be increased. Most fabricated rotors are de-
signed to withstand a peripheral speed of 10,000 feet per minute [3,048 meters
per minute]. If this speed is exceeded, the rotor may fly apart. Table 14.1 lists
the maximum diameters of rotors for various poles when operating on 60, 50
or 25 hertz.
Table 14.1
Maximum Rotor Diameters
Inches Millimeters
Poles
60 HZ 50 HZ 25 HZ 60 HZ 50 HZ 25 HZ
2 10.6 12.7 25.5 269 323 648
4 21.2 25.5 50.9 538 648 1293
6 31.8 38.2 808 970
8 42.4 50.9 1077 1293
Although you may receive a motor for rewind that has a rotor diameter ex-
ceeding the diameters shown in Table 14.1, you can assume that the manu-
facturer originally designed the rotor to withstand a peripheral speed of more
than 10,000 feet per minute [3,048 meters per minute] .
After making sure that the rotor can stand the increase in speed, the next step
is to check the stator-rotor slot combination by referring to Table 14.2. (See
Pages 45 - 48 for an explanation of how to use this table.)
The formulas for calculating the power output and synchronous rpm of a
motor are:
T x rpm TM x rpm
hp = hp =
5250 7120
TM x rpm
kW = Syn. rpm = 120 x hertz
9550 poles

where:

T = torque in pound-feet


rpm = operating speed

Table 14.2
2 1, 2, 3, 4 6, 12, 18, 24 2, -4, -10

4 1, 2, 3, 4, 5, 6 12, 24, 48, 60 4, -8, -20
6 1, 2, 4, 5, 7, 8 18, 36, 54, 72 6, -12, -30
8 1, 2, 6, 7, 9, 10 24, 48, 72 8, -16, -40
10 1, 2, 8, 9, 11, 12 30, 60, 90 10, -20, -50
12 1, 2, 10, 11, 13, 14 36, 72 12, -24, -60
14 1, 2, 12, 13, 15, 16 42 14, -28
16 1, 2, 14, 15, 17, 18 48 16, -32
18 1, 2, 16, 17, 19, 20 54 18, -36
20 1, 2, 18, 19, 21, 22 60 20, -40
24 1, 2, 22, 23, 25, 26 72 24, -48
32 1, 2, 30, 31, 33, 34 96 32, -64
36 1, 2, 34, 35, 37, 38 108 36, -72
48 1, 2, 46, 47, 49, 50 144 48, -96
Output These formulas indicate that the output power will change in inverse propor-
Limitations tion to the change in the number of poles if the torque is kept constant.
However, there are design limitations to consider when number of poles is
decreased. For instance, a motor can NEVER be redesigned for two-pole oper-
ation with an increase in output power in the inverse ratio of the pole change.
In most cases, the output power cannot be increased at all and sometimes may
even have to be decreased. The reason is insufficient back iron. Thus, when
decreasing poles, the back-iron density becomes the governing factor.
In a given frame size, a manufacturers two-pole motors always have a

smaller bore than his motor designs for more than two poles. One reason for
this is that more back iron is needed for two-pole motors. Some manufacturers
have a second bore diameter for their four-pole motors and a third diameter
for motors with six and more poles. Others have only two bore diameters, one

for two-pole motors and another for four and more poles. Still other manu-
facturers have two diameters in their small frames and three diameters in their
larger frames.
Where a manufacturer uses three bore diameters, it may not be possible to
redesign a six- or eight-pole motor for four-pole operation and increase the
output power in inverse proportion to the pole change without increasing the
temperature rating of the insulation system. Excessive heat would be generat-
ed in the back iron because the back-iron density would have to be quite high.
To determine ahead of time whether or not the output can be increased in
inverse proportion to the pole change without over-saturating the back iron,
compare your bore diameter with diameters shown in EASAs Rewind Data
On CD-ROM. Locate data on the CD for the same manufacturer, the same
frame diameter and the same series at the new rpm. If the diameter of your
motor is larger than the diameter shown on the CD, you may have trouble with
back-iron saturation. It may be necessary to consider a lower output power
than shown on the CD. (Series refers to todays motors and pre-1960 motors.
Do not, for example, compare todays bore diameter with that shown for pre-
1960 frames.)
The previous discussion on bore diameters pertains to NEMA and IEC frame
motors. For motors built in frames larger than a NEMA 680 frame (shaft
height = 17 inches or 432 millimeters), manufacturers usually use a different
bore diameter for each synchronous speed. Thus, on larger motors the output
power increase may have to be smaller than that indicated by the formula on
Page 57, when the number of poles are decreased.
Fan And Be extremely careful when increasing speed on a motor that is used to drive
Pump Loads a fan. Fan loads vary as the cube of the speed (rpm)3. An increase in speed
would therefore require an increase in output power greater than the ratio of
the speed increase. Unless the motor is underloaded to begin with, it may not
be possible to increase motor speed on a fan application.
The load curve for a centrifugal pump is similar to that of a fan. Most centrif-
ugal pumps use a two-pole or a four-pole motor. Thus, it would be impossible
to increase the speed of a motor on this type of application.
Connection Before beginning your calculations, you must determine the type of con-
Choice nection (star or delta), the number of parallel circuits, and the span for the
redesign. Frequently when the number of poles is changed, not all groups
will have the same number of coils. This limits the number of parallel cir-
cuits, since each leg of the parallel circuit must contain the same number of
coils. Refer to the Coil Grouping Chart on Pages 122 - 123. The choice of a

c onnection depends on the output rating, voltage rating, the number of pos-
sible parallel circuits and the volts per coil (suggested maximum = 40 volts).
A span should be chosen that has a chord factor close to .966, unless the poles
are to be decreased to two. The chord factor for two-pole motors should be
between .707 and .866 (see the discussion on chord factor, Pages 23 - 26).
Sample Original nameplate data: 50 hp, 1775 rpm, 230/460 volts, 60 hertz,
Redesign 326T frame, 3 phase, DP.
1-12, connected 4 and 2 delta, chord factor = .991 (see Table 14.3).
Core data (in inches): 48 slots, bore 9.0 , core length 7.25, tooth width .313,
back iron 1.375, 35 rotor bars (refer to Figures A and B, Page 124).
Desired new rating: 50 hp, 3600 rpm, 230/460 volts, 60 hertz, 3 phase.
Stator-rotor slot combination is okay. Assume a 2 and 1 delta connection,

span 1-13 (chord factor = .707, see Table 14.3), grouping - 6 groups of 8
coils, distribution factor - .956 (see Table 14.4).
phase volts 460

Volts per coil = = = 28.8 volts
coils in series 2 x 8
For a delta connection, phase voltage equals line voltage. For a star con-
nection phase voltage is 58 percent of line voltage. For a two-pole motor
connected series, there are two groups in series. With eight coils per group,
there will be 16 coils (2 x 8) in series.
Calculate the turns using the Master Formula (Page 29).

E2 CF1 N2
13 x x x x 460 x .991 x 1 x 1.0

=
460 .707 2
To get the calculated turns closer to a whole number, increase the span to 1-14
(chord factor = .752; see Table 14.3).
.707
T2 = 6.44 x = 6.06
.752

Table 14.3
Chord Factor
SLOTS PER POLE
Coil
Span 24 22 20 18 16 15 12 11 10 9 8 6 4 3
1-25 1.000 .990 .951 .866

1-24 .998 .997 .972 .906
1-23 .991 1.000 .988 .940 .831
1-22 .981 .997 .997 .966 .882
1-21 .966 .990 1.000 .985 .924 .866
1-20 .947 .977 .997 .996 .957 .914
1-19 .924 .959 .988 1.000 .981 .951
1-18 .897 .937 .972 .996 .995 .978 .793
1-17 .866 .910 .951 .985 1.000 .995 .863 .756
1-16 .831 .878 .924 .966 .995 1.000 .924 .841 .707
1-15 .793 .841 .891 .940 .981 .995 .966 .910 .809 .643
1-14 .752 .801 .853 .906 .957 .978 .991 .960 .891 .766
1-13 .707 .756 .809 .866 .924 .951 1.000 .990 .951 .866 .707
1-12 .707 .760 .819 .882 .914 .991 1.000 .988 .940 .831
1-11 .707 .766 .831 .866 .966 .990 1.000 .985 .924
1-10 .707 .743 .809 .924 .960 .988 1.000 .981 .707
1- 9 .643 .707 .743 .866 .910 .951 .985 1.000 .866
1- 8 .634 .669 .793 .841 .891 .940 .981 .966
1- 7 .556 .588 .707 .756 .809 .866 .924 1.000 .707
1- 6 .500 .609 .655 .707 .766 .831 .966 .924
1- 5 .588 .643 .707 .866 1.000 .866
1- 4 .556 .707 .924 1.000
1- 3 .707 .866

( ) = Sin70 =.940
slots/pole
36/4
nected 1 delta for 460 volts.
Flux per pole =
hertz x coils x turns per coil x chord factor x dist. factor

22,500,000 x 460 x 3 x 1
= = 2,499,437 magnetic lines
60 x 48 x 6 x .752 x .956 of flux per square inch
flux per pole

Back-iron density =
2 x core length x back iron x .95
2,499,437
= = 131,962 magnetic lines
2 x 7.25 x 1.375 x .95 of flux per square inch

Air-gap density =
3.14 x bore x core length
1.57 x 2,499,437 x 2
3.14 x 9 x 7.25 of flux per square inch
Tooth density =
core length x slots x tooth width x .95
1.57 x 2,499,437 x 2
7.25 x 48 x .313 x .95 of flux per square inch
Table 14.4

1 1.000 1.000 1.0
2 .966 .837 1.0
3 .960 .831 1.0
4 .958 .829 1.0

5 .957 .828 1.0
6 or more .956 .827 1.0

180
A =
slots per pole
Sin ( 2
A x B
) (
A x B
Sin
2
)
DF =
slots
DF = B =
poles x phases
A
B x Sin
2
( ) 30
( )
2 x B x Sin
for wound poles.)

Although the torque has been cut in half, the back-iron density is very high
while the air-gap and tooth densities are rather low (see Flux Densities, Table
14.5). This is usually the case when the new number of poles is two. The
winding is acceptable with a Class H (180C) insulation system. If your den-
sities are too high or too low, refer to Pages 89 - 93.
Table 14.5


centimeter.
To complete the redesign, we must now calculate the new wire size using the
formula from Page 1:
T
CM2 = CM1x 1
T2
From Table O on Page 120, the circular mil area of #18 wire (AWG) is 1620.
CM1 = 4x1620 = 6480 circular mils

13
CM = 6480x = 14040 circular mils
6
1-#14 and 3-#15 wires (AWG) = 4110 x (3 x 3260) = 13890 circular mils

For a 50 horsepower motor operating on 460 volts, the approximate full-load
current is 65 amperes. (See Table F, Page 115.)

phase amperes
For a delta connection, phase amperes are 58 percent of line amperes. For a
13890 x 1
Circular mils per ampere = = 368 circular mils per ampere
.58 x 65
The calculated wire is large enough to carry the full-load amperes of this mo-
tor.
The new winding data will be 6 turns per coil, 1-#14 and 3-#15 wire (AWG),
span 1-14, connected 2 and 1 circuit delta.
Table 14.6
Pre-1960 Motors 430 550


15 Single-Speed To Two-Speed, One Winding
For the vast majority of motors, there should always be a two-to-one speed
ratio if the design is to be changed from single-speed to two-speed, one wind-
ing. The only exceptions to this rule are the Pole-Amplitude Modulation
motors that were developed in the 1960s, for which any desired speed ratio
may be obtained from one winding.
P.A.M. Called P.A.M. motors for short, most Pole-Amplitude Modulation motors
Motors are manufactured in Europe, though some have been shipped to the United
States.
P.A.M. motors have six leads and are externally connected like a standard
two-speed, one winding motor. Internally, the connection and grouping is
more complicated. They are mentioned here only to make you aware of their
existence. No attempt will be made here to show how they are designed.
Output There are three types of two-speed, one winding motors. The method of con-
And Speed necting them and their horsepower ratios are shown in Table 15.1.
Ratios
Table 15.1
Connections* Hp Ratio
Type
High Low High/Low Speed
Constant Hp 1D 2Y 1/1
Constant Torque 2Y 1D 2/1
Variable Torque 2Y 1Y 4/1
* The connections may be multiples of those shown in the table.
The horsepower ratios in Table 15.1 are for motors manufactured in North
America. Output ratios of motors manufactured in other parts of the world are
much closer. For instance, for a constant-torque connection, the output rating
may be something like 1.8/1.3 kW instead of 1.8/.9 kW.
Multispeed motors should be designed for one voltage if possible. Although

they can be designed for dual voltage, the external connection would require
18 leads. Dual-voltage, two/four pole motors have been built using two iden-
tical windings on top of one another that are put in series on high voltage and
paralleled on low voltage. When redesigning for two-speed, one-winding, be

sure to check the stator-rotor slot combination for both speeds (Table 15.2).
(See Pages 45 - 48 for an explanation of how to use this table.)
Table 15.2
2 1, 2, 3, 4 6, 12, 18, 24 2, -4, -10

4 1, 2, 3, 4, 5, 6 12, 24, 48, 60 4, -8, -20
6 1, 2, 4, 5, 7, 8 18, 36, 54, 72 6, -12, -30
8 1, 2, 6, 7, 9, 10 24, 48, 72 8, -16, -40
10 1, 2, 8, 9, 11, 12 30, 60, 90 10, -20, -50
12 1, 2, 10, 11, 13, 14 36, 72 12, -24, -60
14 1, 2, 12, 13, 15, 16 42 14, -28
16 1, 2, 14, 15, 17, 18 48 16, -32
18 1, 2, 16, 17, 19, 20 54 18, -36
20 1, 2, 18, 19, 21, 22 60 20, -40
24 1, 2, 22, 23, 25, 26 72 24, -48
32 1, 2, 30, 31, 33, 34 96 32, -64
36 1, 2, 34, 35, 37, 38 108 36, -72
48 1, 2, 46, 47, 49, 50 144 48, -96
Choosing The span should be as close to half-pitch as possible for the high-speed wind-
The Span ing. A half-pitch span has a chord factor of .707. There must be an even
number of coils per group to have a .707 chord factor. With an odd number
of coils per group, start with a span that has a chord factor slightly above .707
for a variable-torque motor, and slightly below .707 for a constant-torque or
constant-horsepower motor.
Low Speed The low-speed air-gap density will usually be between 55,000 and 70,000
Air-Gap lines per square inch [8,525 to 10,850 lines per square centimeter] for a
Densities constant-torque or constant-horsepower motor. Exceeding 70,000 lines per
square inch [10,850 line per square centimeter] will cause excessive magne-
tizing current to flow, thus further reducing the efficiency and power factor
which, in this type of motor, are low to begin with.

Output In some redesigns of this kind, it may be desirable to keep the high-speed rat-
Ratings ing the same as the original single-speed rating. This can be accomplished for
all variable-torque motors and most constant-torque motors of the pre-1960
era by using an insulation system that is rated for a higher temperature. The
temperature rise, in this case, increases because the shorter span requires more
turns. More turns in the same slot also means a smaller wire must be used,
which causes the copper losses to rise. Normally two-speed, one winding mo-
tors are built in a larger frames than single-speed motors with the same rating
as the high speed.
If a single-speed motor from your stock is to be redesigned into a two-speed,

one winding, four/eight pole motor, use a six-pole motor in the desired frame
rather than a four-pole motor, if possible. Six-pole motors sometimes have
larger bore diameters, so for a given flux per pole, they will have a lower air-
gap density. This is particularly important on the low speed. Before going
further, however, first compare the rotor diameter with the diameters shown in
Table C, Page 114.
Next, calculate the turns per coil using the Master Formula based on the high-
speed rating and connection.
Sample Original nameplate data: 20 hp, 1760 rpm, 230/460 volts, 60 hertz, 256
Tframe, DP.
Redesign
1-11, connected 2 and 1 circuit delta, chord factor = .966 (see Table 15.3).
Core data (in inches): 48 slots, bore 6.25, core length 6.875, tooth width .25,
back iron 1, 35 rotor bars (refer to Figures A and B, Page124).
Desired new ratings: 15/7.5 hp, 1800/900 rpm, 575 volts, 60 hertz, 3 phase.
The stator-rotor slot combination is okay. The horsepower rating is a two-to-
one ratio, so this is a constant-torque motor and the connection will be 2Y-1
delta. There are 12 slots per pole for the high speed (48/4 = 12), so to obtain
a chord factor of .707 the span would be 1-7 (see Table 15.3).
Calculate the turns by the Master Formula (Page 29).
E2 CF1 N2
575 x .966 x 2 x .58
= 10 x x x x
460 .707 1


Calculate the densities for both speeds based on a winding of 23 turns per coil,
span 1-7, connected 2Y and 1 delta for 575 volts.
Table 15.3
Chord Factor
SLOTS PER POLE
Coil
Span 24 22 20 18 16 15 12 11 10 9 8 6 4 3
1-25 1.000 .990 .951 .866

1-24 .998 .997 .972 .906
1-23 .991 1.000 .988 .940 .831
1-22 .981 .997 .997 .966 .882
1-21 .966 .990 1.000 .985 .924 .866
1-20 .947 .977 .997 .996 .957 .914
1-19 .924 .959 .988 1.000 .981 .951
1-18 .897 .937 .972 .996 .995 .978 .793
1-17 .866 .910 .951 .985 1.000 .995 .863 .756
1-16 .831 .878 .924 .966 .995 1.000 .924 .841 .707
1-15 .793 .841 .891 .940 .981 .995 .966 .910 .809 .643
1-14 .752 .801 .853 .906 .957 .978 .991 .960 .891 .766
1-13 .707 .756 .809 .866 .924 .951 1.000 .990 .951 .866 .707
1-12 .707 .760 .819 .882 .914 .991 1.000 .988 .940 .831
1-11 .707 .766 .831 .866 .966 .990 1.000 .985 .924
1-10 .707 .743 .809 .924 .960 .988 1.000 .981 .707
1- 9 .643 .707 .743 .866 .910 .951 .985 1.000 .866
1- 8 .634 .669 .793 .841 .891 .940 .981 .966
1- 7 .556 .588 .707 .756 .809 .866 .924 1.000 .707
1- 6 .500 .609 .655 .707 .766 .831 .966 .924
1- 5 .588 .643 .707 .866 1.000 .866
1- 4 .556 .707 .924 1.000
1- 3 .707 .866

( ) = Sin70 =.940
slots/pole
36/4

Table 15.4

1 1.000 1.000 1.0
2 .966 .837 1.0
3 .960 .831 1.0
4 .958 .829 1.0
5 .957 .828 1.0
6 or more .956 .827 1.0

180
A =
slots per pole
(
A x B
Sin 2 ) (
A x B
Sin
2 )
DF =
slots
DF = B =
poles x phases
A
B x Sin
2
( ) 30
( )
2 x B x Sin
for wound poles.)
From Tables 15.3 and 15.4:
High-speed chord factor = .707 high-speed dist. factor = .958
Low-speed chord factor = 1.0 low-speed dist. factor = .829

Flux per pole =
22,500,000 x 332 x 3 x 2
High speed = = 999,000 magnetic lines

Flux per pole 60 x 48 x 23 x .707 x .958
of flux per pole
22,500,000 x 575 x 3 x 1
Low speed


Flux per pole 60 x 48 x 23 x 1.0 x .829
of flux per pole
flux per pole
Back-iron density =
999,000
High speed = = 76,478 magnetic lines of

Back-iron density 2 x 6.875 x 1 x .95 of flux per pole
706,800
Low speed = = 54,109 magnetic lines of

Back-iron density 2 x 6.875 x 1 x .95
of flux per pole

Air-gap density =

High speed 1.57 x 999,000 x 4
Air-gap density = = 46,475 magnetic lines of
3.14 x 6.25 x 6.875 flux per square inch

Low speed 1.57 x 706,800 x 8
Air-gap density = = 65,763 magnetic lines of
3.14 x 6.25 x 6.875 flux per square inch

Tooth density =

High speed 1.57 x 999,000 x 4
Tooth density = = 80,048 magnetic lines of
6.875 x 48 x .25 x .95 flux per square inch

Low speed 1.57 x 706,800 x 8
Tooth density = = 113,268 magnetic lines of
Note that the low-speed air-gap density is quite high, but this is to be expected
with constant-torque or constant-horsepower motors. The winding is there-
fore acceptable. If densities are too high or too low, refer to Pages 89 - 93.
To complete the redesign, we must now calculate a new wire size using the
formula from Page 1.
T
CM2 = CM1 x 1
T2
From Table O, Page 120, the circular mil area of a #15 wire (AWG) is 3260.

10

23
2-#20 and 1-#21 wires (AWG) = (2 x 1020) + 812 = 2852 circular mils
For a 15 horsepower motor operating on 575 volts, the approximate full-load

current is 17 amperes. (See Table F, Page 115.)

phase amperes

For a star connection, phase amperes equal line amperes. For a delta connec-
tion, phase amperes equal 58 percent of line amperes. It is only necessary to
check circular mils per ampere for the high speed since the circular mils per
ampere for the low speed will be approximately the same for a constant-torque
motor.
2852 x 2
Circular mils per ampere = = 336 circular mils per ampere
17
Table 15.5
Pre-1960 Motors 430 550

The calculated wire is large enough to carry the full-load amperes of this
motor.
The new winding data will be 23 turns per coil, 2-#20 and 1-#21 wires
(AWG), span 1-7, connected 2Y for 1800 rpm and 1 delta for 900 rpm
operation.

16 Single-Speed To Two-Speed,
Two Windings
Changing a design from single-speed to two-speed, two windings is a redesign

that actually involves making two designs fit into the same core at the same
time. As you might expect, when two windings are to be inserted, there are
more limitations than if only one winding is used.
The first step in making a redesign of this type is to check the stator-rotor slot
combination for both speeds (Table 16.1). If the high speed is to be faster than
the original rpm, the rotor diameter also should be checked with Table C on
Page 114.
Table 16.1
2 1, 2, 3, 4 6, 12, 18, 24 2, -4, -10

4 1, 2, 3, 4, 5, 6 12, 24, 48, 60 4, -8, -20
6 1, 2, 4, 5, 7, 8 18, 36, 54, 72 6, -12, -30
8 1, 2, 6, 7, 9, 10 24, 48, 72 8, -16, -40
10 1, 2, 8, 9, 11, 12 30, 60, 90 10, -20, -50
12 1, 2, 10, 11, 13, 14 36, 72 12, -24, -60
14 1, 2, 12, 13, 15, 16 42 14, -28
16 1, 2, 14, 15, 17, 18 48 16, -32
18 1, 2, 16, 17, 19, 20 54 18, -36
20 1, 2, 18, 19, 21, 22 60 20, -40
24 1, 2, 22, 23, 25, 26 72 24, -48
32 1, 2, 30, 31, 33, 34 96 32, -64
36 1, 2, 34, 35, 37, 38 108 36, -72
48 1, 2, 46, 47, 49, 50 144 48, -96
Redesigns of this kind should be for a single voltage only. Both windings
should be designed for a 1Y connection if at all possible. In cases where
parallel circuits must be used, care must be taken to connect the poles in a
manner that will prevent currents from circulating in the unenergized wind-
ing. Parallel circuits should only be attempted if there is even coil grouping
on both windings.

Eliminating Figures 16.1 and 16.2 illustrate two ways that four poles can be connected in
Circulating a series-parallel combination. The arrows show the direction that the induced
Currents current is flowing at a given instant. Assume the values of the induced cur-
rents are equal.
Figure 16.1 Figure 16.2
Figure 16.1 is connected incorrectly. The currents induced in the unener-

gized winding will circulate and, by transformer action, induce currents in the
energized winding. The no-load current therefore will be considerably above
nameplate current.
Figure 16.2 is connected correctly. Since the currents induced in each leg of
the parallel circuit are flowing in opposite directions, they cancel one another.
Therefore, when operating on the other winding, the motor will act as if the
parallel-connected winding is not there.
Table 16.2 gives the number of poles that must be connected in series in each
leg of the parallel circuit for various speed ratios to eliminate circulating cur-
rents. Multiples of the figures shown can also be used. As can be seen, some-
times it is necessary to use a 1-4 connection, sometimes a 1-7, and other times
both will work. In still other cases, parallel circuits cannot be used.
If you have a four- and eight-pole, two-winding motor (speed ratio two-to-
one) and wish to use two circuits for the high speed, Table 16.2 shows that a
1-4 internal connection must be used. If a two-circuit connection were used
on the low speed, four poles would be in series in each leg. Four is what is
needed for a 1-4 connection and, since four is a multiple of two, a 1-7 connec-
tion could also be used. If a four-circuit connection were used, there would
be two poles in series in each leg of the parallel circuit. Although this is not
enough for a 1-4 connection, a 1-7 connection would work.
For a four- and six-pole motor with a two-star connection on each winding, a
1-7 jumper must be used on both windings. This is a three-to-two speed ratio.
The four-pole winding has two poles in series, and the six-pole winding has
three poles in series. Table 16.2 shows there are not enough coils in series
for 1-4 jumper, but a 1-7 jumper requires only two and three poles in series
(respectively) to work successfully.

Table 16.2
Parallel Circuits For Two-Winding Motors
High-Speed Winding
Speed Ratio Adjacent Pole (1-4) Skip Pole (1-7)
3/1, 5/1, 7/1, etc. Impossible Impossible
2/1, 4/1, 6/1, etc. 2 Impossible
3/2, 5/2, 7/2, etc. 4 2
4/3, 8/3, 10/3, etc. 6 3
5/3, 7/3, 11/3, etc. 3 3
5/4, 7/4, 9/4, etc. 8 4
6/5, 8/5, 12/5, etc. 10 5
7/5, 9/5, 11/5, etc. 5 5
Low-Speed Winding
Speed Ratio Adjacent pole (1-4) Skip Pole (1-7)
2/1 4 2
3/1 3 3
3/2 6 3
4/1, 4/3 8 4
5/1, 5/3 5 5
5/2, 5/4 10 5
6/1, 6/5 12 6
7/1, 7/3, 7/5 7 7
7/2, 7/4, 7/6 14 7
On some large motors, a three-circuit connection is used on a six-pole wind-

ing. The only way this will work is with a 1-10 internal connection.
Sometimes it may be necessary to use a delta connection. In such cases, it is

advisable to bring out four leads, opening up one corner of the delta for test
purposes. If circulating currents are present, it will be necessary to have four
leads on that winding. This necessitates the use of a four-pole starter for that
winding.

Numbering The high-speed leads should be numbered 11, 12 and 13, and the low-speed
The Leads leads should be numbered 1, 2 and 3. When testing the motor in your service
center, be sure leads 11 and 1 are connected to the same line from the power
source. The same holds true for leads 12 and 2, and 13 and 3. Note the direc-
tion of rotation, which must be the same on both windings.
Output The output ratings for each speed will have to be lower than the rating of the
Ratings original motor. How much they will decrease depends on the type of motor,
the speed ratio and the desired temperature rise. For a constant-horsepower
motor, the horsepowers are the same on both speeds. For a constant-torque
motor, the horsepower ratio is the same as the speed ratio. For a variable-
torque motor, the horsepower ratio is the square of the speed ratio. Base the
estimated temperature rise on the circular mils per ampere, because the tooth,
back-iron and air-gap densities normally will be low. The circular mils per
ampere value also will be quite low for both windings, possibly less than 200
for each of them.
Turns To calculate the turns for each winding, use the Master Formula, and then
Calculation multiply the low-speed turns by a correction factor of between 0.95 and 0.8,
depending on the output power and pole change. The greater the change, the
smaller should be the correction factor. Except when the whole number is
less than 10 and the partial turn is greater than 0.5, the turns for both windings
usually should be rounded off downwards.
For high-speed windings, where the number of poles change, the tooth, back-
iron and air-gap densities should be calculated. Before beginning the turns
calculations, however, determine the type of connection (star or delta), the
number of parallel circuits and the span for each winding. Unless there is
only one coil per group, the span for each winding should have a chord factor
of less than 1.0, but be as close to 1.0 as possible.
Wire Size To calculate the wire size, first determine the total circular mil area per coil
Calculation side for the original winding by multiplying the circular mil area of each size
times the number of strands, times the number of turns. Next, calculate 3/8,
1/2 and 5/8 of the total circular mil area per coil side. Then divide 3/8 and
1/2 of the total circular mil area by the turns in the high-speed winding, and
1/2 and 5/8 of the total circular mil area by the turns in the low-speed winding.
This gives a range from which to choose the wire size for each winding.

For a constant-horsepower motor, the wire size of the high-speed winding
should be as close as possible to the 3/8 value, wheras the wire size for the
low-speed winding should be as close as possible to the 5/8 value. On a
variable-torque motor, the wire size for each winding should be as close as
possible to the 1/2 values. For a constant-torque motor, choose a wire size as
close as possible to the middle of the range for each winding.
When the wire size for each winding has been selected, multiply the circular
mil area per turn of each winding by the turns for that winding and add these
values. The total must be less than the circular mil area per coil side of the
original winding, because three center separators will now be needed instead
of just one.
Next, calculate the circular mils per ampere for both windings. The low-speed
value should be the higher of the two. The greater the difference in the speeds
of the two windings, the greater should be the difference in their circular mils
per ampere values. This is necessary because the motor cannot dissipate the
heat as readily when operating on the lower speed. If necessary, adjust both
wire sizes.
Sample Original nameplate data: 5 hp, 1150 rpm, 230/460 volts, 60 hertz, 215T
Redesign frame, 3 phase, dripproof.
1-6, connected 2 and 1Y, chord factor = .966 (see Table 16.3).
Core data (in inches): 36 slots, bore 6, core length 3, tooth width .235, back
iron .562, 47 rotor bars (refer to Figures A and B, Page 124).
Desired new rating: 3/1 hp, 4/12 poles, 460 volts, 60 hertz, 3 phase.
The stator-rotor slot combination is okay. Use a 1Y connection for both

windings. Use a high-speed span of 1-9 (chord factor = .985), and a low-
speed span of 1-4 (chord factor = 1.0). (For chord factors, see Table 16.3).
The high-speed winding will have 12 groups of three coils, and the low-speed
winding will have 36 groups of one coil. Distribution factors are .96 for the
high-speed winding, and 1.0 for the low-speed winding (see Table 16.4).
Calculate the turns for both windings using the Master Formula (Page 29).
E2 CF1 N2
T = T1 x x x x E1 x CF2 x N1 xCC

Table 16.3
Chord Factor
SLOTS PER POLE
Coil
Span 24 22 20 18 16 15 12 11 10 9 8 6 4 3
1-25 1.000 .990 .951 .866

1-24 .998 .997 .972 .906
1-23 .991 1.000 .988 .940 .831
1-22 .981 .997 .997 .966 .882
1-21 .966 .990 1.000 .985 .924 .866
1-20 .947 .977 .997 .996 .957 .914
1-19 .924 .959 .988 1.000 .981 .951
1-18 .897 .937 .972 .996 .995 .978 .793
1-17 .866 .910 .951 .985 1.000 .995 .863 .756
1-16 .831 .878 .924 .966 .995 1.000 .924 .841 .707
1-15 .793 .841 .891 .940 .981 .995 .966 .910 .809 .643
1-14 .752 .801 .853 .906 .957 .978 .991 .960 .891 .766
1-13 .707 .756 .809 .866 .924 .951 1.000 .990 .951 .866 .707
1-12 .707 .760 .819 .882 .914 .991 1.000 .988 .940 .831
1-11 .707 .766 .831 .866 .966 .990 1.000 .985 .924
1-10 .707 .743 .809 .924 .960 .988 1.000 .981 .707
1- 9 .643 .707 .743 .866 .910 .951 .985 1.000 .866
1- 8 .634 .669 .793 .841 .891 .940 .981 .966
1- 7 .556 .588 .707 .756 .809 .866 .924 1.000 .707
1- 6 .500 .609 .655 .707 .766 .831 .966 .924
1- 5 .588 .643 .707 .866 1.000 .866
1- 4 .556 .707 .924 1.000
1- 3 .707 .866
(
Chord factor=Sin 90x
teeth spanned
( ) = Sin70 =.940
slots/pole
36/4
High speed:
460 x .966 x 1 x 1
T = 23 x x x x
460 .985 1
= 23.8 turns per coil. Use 23 turns per coil.
Low speed:
460 x .966 x 1 x 1
T = 23 x x x x
460 1.0 1
= 70.3 turns per coil.

As indicated on Page 75, the low-speed turns must be multiplied by a correc-
tion factor between 0.95 and 0.8. A factor of 0.85 was selected in this case.
T = 70.3 x .85 = 59.7 Use 59 turns.
Calculate the high-speed densities based on a winding of 23 turns per coil,

span 1-9, connected 1Y for 460 volts.

Flux per pole =
22,500,000 x 265 x 3 x 1
60 x 36 x 23 x .985 x .96 of flux per pole
flux per pole

Back-iron density =
380,768
= = 118,864 magnetic lines of
2 x 3 x .562 x .95 flux per square inch
Table 16.4

1 1.000 1.000 1.0
2 .966 .837 1.0
3 .960 .831 1.0
4 .958 .829 1.0
5 .957 .828 1.0
6 or more .956 .827 1.0

180
A =
slots per pole
(
A x B
Sin 2 ) (
A x B
Sin
2 )
DF =
slots
DF = B =
poles x phases
A
B x Sin
2
( ) 30
( )
2 x B x Sin
for wound poles.)

Air-gap density =
1.57 x 380,768 x 4
3.14 x 6 x 3 flux per square inch

Tooth density =
1.57 x 380,768 x 4
3 x 36 x .235 x .95 flux per square inch
Wire Size From Table O, Page 121, #21 wire (AWG) has an area of 812 circular mils.
Calculation Circular mil area per coil side = 812 x 3 x 23 = 56,028 circular mils
3
x 56,028 = 21,010 circular mils
8
4
8
5
8
For high speed:

21,010 28,014
CM = = 913.5 circular mils and = 1218 circular mils
23 23

For low speed:

28,014 35,017
CM = = 475 circular mils and = 594 circular mils
59 59
Since this is a constant-torque motor (horsepower and speed ratios are both
three-to-one), choose wire sizes nearest to the middle of both ranges.
The circular mil area of #23 wire (AWG) is 511; of #24 wire (AWG) is 404;
and of #25 wire (AWG) is 320 (Table O, Page 121).

High speed:
CM = 1-#24 and 2-#25 = 404 + (2 x 320) = 1,044 circular mils
Low speed:
CM = 1-#23 = 511 circular mils
The circular mil area of the two coil sides together is:
CM = (T x CMHigh) + (T x CMLow)
= (23 x 1,044) + (59 x 511) = 54,161 circular mils
Since 54,161 circular mils is less than the 56,028 circular mils calculated for
the original single-speed winding, it should fit into the slot.
The approximate full-load amperes are 4.8 for a 3 horsepower, 460-volt motor,
and 1.8 for a 1 horsepower, 460-volt motor (see Table F, Page 115).
phase amperes
For a star connection, phase amperes equal line amperes. For a delta connec-
tion, phase amperes equal 58 percent of line amperes.
High speed:
1044 x 1
CM/A = = 217 circular mils/ampere
4.8
Low speed:
511 x 1
CM/A = = 284 circular mils/ampere
1.8
The circular mils per ampere for the low-speed winding are larger than the
circular mils per ampere of the high-speed winding.
The new high-speed winding will be 23 turns per coil, 1-#24 and 2-#25 wires
(AWG), span 1-9, connected one-star. The new low-speed winding will be 59
turns per coil, 1-#23 wire (AWG), span 1-4, connected one-star.

17 Developing A Winding For A Bare Core
The method described here can be used to calculate a three-phase winding for
a core when the original data has been lost, a stator does not have a winding in
it, or a single-phase motor is to be redesigned to operate as a three-phase mo-
tor. In the latter case, count the turns and measure the wire size in the fullest
slot, normally the outside coil of the running winding. This will enable you to
calculate the new wire size accurately.
If the nameplate is missing or if the motor is to operate at a different speed,

check the stator-rotor slot combination with Table 17.1. (Discussion pertain-
ing to this table is on Pages 45 - 48.) You should also check the rotor diameter
with Table 17.2 (see Page 57 for an explanation of this table).
Table 17.1
2 1, 2, 3, 4 6, 12, 18, 24 2, -4, -10

4 1, 2, 3, 4, 5, 6 12, 24, 48, 60 4, -8, -20
6 1, 2, 4, 5, 7, 8 18, 36, 54, 72 6, -12, -30
8 1, 2, 6, 7, 9, 10 24, 48, 72 8, -16, -40
10 1, 2, 8, 9, 11, 12 30, 60, 90 10, -20, -50
12 1, 2, 10, 11, 13, 14 36, 72 12, -24, -60
14 1, 2, 12, 13, 15, 16 42 14, -28
16 1, 2, 14, 15, 17, 18 48 16, -32
18 1, 2, 16, 17, 19, 20 54 18, -36
20 1, 2, 18, 19, 21, 22 60 20, -40
24 1, 2, 22, 23, 25, 26 72 24, -48
32 1, 2, 30, 31, 33, 34 96 32, -64
36 1, 2, 34, 35, 37, 38 108 36, -72
48 1, 2, 46, 47, 49, 50 144 48, -96
Table 17.3 shows the approximate densities for todays motors with a temper-
ature rise requiring a Class B insulation system, and for pre-1960 motors hav-
ing a temperature rise within the limits of a Class A insulation system. Higher
densities can be used with insulation systems rated for higher temperatures if
the application can stand a motor with a higher temperature rise. For a Class
F insulation system, todays density values can be increased 10 percent. For a
Class H insulation system, the densities can be increased 20 percent.

Table 17.2
Maximum Rotor Diameters
Inches Millimeters
Poles
60 HZ 50 HZ 25 HZ 60 HZ 50 HZ 25 HZ
2 10.6 12.7 25.5 269 323 648
4 21.2 25.5 50.9 538 648 1293
6 31.8 38.2 808 970
8 42.4 50.9 1077 1293
The formula for calculating turns-per-coil asks for the air-gap density, syn-
chronous speed, bore diameter and core length as part of its input. Assume
a reasonable air-gap density (refer to Table 17.3). As is the case for other
redesigns, here it also will be necessary to assume the type of connection (star
or delta), the number of parallel circuits and the span before any calculations
are performed. These variables can be changed later if necessary. When
selecting the number of parallel circuits, watch out for odd grouping, because
this will limit the number of parallels that can be used. Refer to Table P,
Pages 122 - 123.
Table 17.3


centimeter.

The turns-per-coil formula is:
1350 x phase volts x phases x circuits
T/C =
core length x coils x bore diam. x chord fact. x dist. fact. x syn. rpm x air-gap den.
1000 1000
If the calculated turns are not a whole number, round them off to the nearest
whole number. Next, calculate the flux per pole and the air-gap, tooth and
back-iron densities. Compare the calculated air-gap density with the value
used to calculate the turns. If these values are not close, an error has been
made in the calculations.
The turns can now be adjusted to make the motor stronger or weaker, if
desired, depending on the density values for the teeth and back iron.
Estimating One method of estimating the output power of a NEMA frame motor is to
Output determine from the mounting dimensions what frame size you have. Your
Power new output power will be the horsepower that NEMA has assigned to that
frame, provided your calculated densities are reasonably close to the values
shown in Table 17.3.
Another method is to take known data from a motor with similar core di-
mensionsi.e., the same rpm, the same frame diameter and vintageand
calculate output power by the following formula:
GCL2 x B2
hp2 = hp1 x x
GCL1 x B1
where:
hp = horsepower (you can also use kW1 and kW2)
GCL = gross core length
B = bore diameter
AGD = air-gap density
Subscript 1 = data from reference motor
Subscript 2 = data from your motor

Estimating Once the output power is known, the approximate wire size can be deter-
Wire Size mined. Use the circular mil per ampere method with Table 17.4 as a guide.
Table 17.4
Pre-1960 Motors 430 550

The formula is:
phase amperes x circular mils per amp

Circular mils per turn =
circuits
where:
Phase amperes = line amperes for star connection
= .58 x line amperes for delta connection
For line amperes, see Table F, Page 115.
When this method is used, make only two coils and test them for slot fill.
Adjust the wire size up or down until you get a snug fit.
Another method is to cut strips of a certain wire size and determine how many
strips you can fit into the slot. Multiply this number by the circular mil area
of the wire and divide by the number of turns you need to insert into the slot.
This will give you the circular mil area per turn.
If you are starting with a single-phase winding, multiply the circular mil area
per turn by the number of turns in the largest coil of the run winding. This
will give you the circular mil area that the entire slot can hold. To get the new
circular mil area per turn, divide this value by two times the number of turns
per coil in the new three-phase winding.

Sample Original nameplate data: unknown.
Redesign Original winding data: unknown.
Core data (in inches): 60 slots, bore 10, core length 7.5, tooth width .25, back
iron 1.5, 71 rotor bars (refer to Figures A and B Page 124 ).
Desired new rating: 1200 rpm, 230/460 volts, 60 hertz; densities to be within
the present day range.
The stator-rotor slot combination is okay. Since there are 12 groups of three
and six groups of four coils (distribution factor = .959, from Table 17.6), we
can only have a 2 and 1 Y, or a 2 and 1 delta connection. Assume the delta
connection with a 1-9 span (chord factor = .951, from Table 17.5). Assume
an air-gap density of 55,000.
phase volts =
460
Volts per coil = = 23 volts
coils in series 20
(Volts per coil should not exceed 40, if possible.)
Turns calculation:
1350 x phase volts x phases x circuits
TC =
core length x coils x bore diam. x chord fact. x dist. fact. x syn. rpm x air-gap den
1000 1000

1350 x 460 x 3 x 1
= = 6.88 turns per coil

7.5 x 60 x 10 x .951 x 959 x 1200 x 55000
1000 1000
Try 7 turns per coil.
Calculate densities based on a winding of 7 turns per coil, 1-9 span connected
1 delta for 460 volts. (A 2 delta connection for 230 volts could be used
instead with the same results.)
Flux per pole =
22,500,000 x 460 x 3 x 1
= = 1,351,000 magnetic lines
flux per pole

Back-iron density =
1,351,000
2x7.5x1.5x.95 flux per square inch

Air-gap density =
1.57 x 1,351,000 x 6
3.14 x 10 x 7.5 flux per square inch

Tooth density =
1.57 x 1,351,000 x 6

Comparing the tooth and back-iron densities with those in Table 17.3 shows
that the tooth density is close to the value shown, while the back-iron density
is quite low. The motor should therefore have a temperature rise within the
limits of a Class B insulation system when operating at full load. The high
tooth density and low core density also indicate that the motor may have origi-
nally been a four-pole motor instead of a six-pole motor.
From EASAs Motor Rewind Data On CD-ROM, we find that data for a 30hp,
six-pole motor has core dimensions close to those in our example.
That data is: 30 hp, 6 pole, 54 slots, 5 turns per coil, span 1-9, 2 star at 230
volts, bore 9.75, core length 6.625. An air-gap density of 54,409 lines per
square inch is also shown in the CD data file.
From Page 83:

GCL2 x B2
hp2 = hp1 x x
GCL1 x B1
7.5 x 10
= 30 x x = 34.3
6.625 x 9.75
This could be called a 35 hp motor.
From Table F on Page 115, the full-load line amperes are 80 for a 30hp motor
at 230 volts, and 104 for a 40 hp motor. The full-load amperes of a 35hp
motor would be halfway between these values, which is 92 amperes.

Table 17.5
Chord Factor
SLOTS PER POLE
Coil
Span 24 22 20 18 16 15 12 11 10 9 8 6 4 3
1-25 1.000 .990 .951 .866

1-24 .998 .997 .972 .906
1-23 .991 1.000 .988 .940 .831
1-22 .981 .997 .997 .966 .882
1-21 .966 .990 1.000 .985 .924 .866
1-20 .947 .977 .997 .996 .957 .914
1-19 .924 .959 .988 1.000 .981 .951
1-18 .897 .937 .972 .996 .995 .978 .793
1-17 .866 .910 .951 .985 1.000 .995 .863 .756
1-16 .831 .878 .924 .966 .995 1.000 .924 .841 .707
1-15 .793 .841 .891 .940 .981 .995 .966 .910 .809 .643
1-14 .752 .801 .853 .906 .957 .978 .991 .960 .891 .766
1-13 .707 .756 .809 .866 .924 .951 1.000 .990 .951 .866 .707
1-12 .707 .760 .819 .882 .914 .991 1.000 .988 .940 .831
1-11 .707 .766 .831 .866 .966 .990 1.000 .985 .924
1-10 .707 .743 .809 .924 .960 .988 1.000 .981 .707
1- 9 .643 .707 .743 .866 .910 .951 .985 1.000 .866
1- 8 .634 .669 .793 .841 .891 .940 .981 .966
1- 7 .556 .588 .707 .756 .809 .866 .924 1.000 .707
1- 6 .500 .609 .655 .707 .766 .831 .966 .924
1- 5 .588 .643 .707 .866 1.000 .866
1- 4 .556 .707 .924 1.000
1- 3 .707 .866

( ) = Sin70 =.940
slots/pole
36/4
Determining Use the circular mil per ampere method to determine the wire size.
Wire Size
phase amperesxcircular mils per ampere
Circular mils per turn =
circuits
.58 x 92 x 330
Circular mils per turn = = 8804 circular mils
2
Phase amps for star = line amps; phase amps for delta = .58 line amps.

From Table O, Page 120, #16 wire (AWG) = 2580 circular mils and
#17 wire (AWG) = 2050 circular mils.
1-#16 and 3-#17 = 2580 + (3 x 2050) = 8730 circular mils.
Make two sample coils of 7 turns of 1-#16 and 3-#17 wire and see how they
fit into the slot.
Table 17.6

1 1.000 1.000 1.0
2 .966 .837 1.0
3 .960 .831 1.0
4 .958 .829 1.0
5 .957 .828 1.0
6 or more .956 .827 1.0

180
A =
slots per pole
(
A x B
Sin 2 ) (
A x B
Sin
2 )
DF =
slots
DF = B =
poles x phases
A
( )
B x Sin
2
30
( )
2 x B x Sin
for wound poles.)

18 Strengthening Or Weakening
A Motor - Short Method
The calculated densities for a redesign will not always be near the values
given in Table 18.1. If they are too high, a high-temperature insulation
system can be used (refer to Pages 42 - 45) or the motor must be weakened.
If they are low, the motor may be strengthened. To strengthen or weaken a
motor, however, it is not necessary to go through the long flux-per-pole and
density calculations again. The proper number of turns can be calculated
more quickly using the ratio (short) method. Of course, strengthening or
weakening the motor will change the rated output power.
The three density formulas are:
Air-gap density = 1.57 x flux per pole x poles

air-gap area
Tooth density = 1.57 x flux per pole x poles

tooth area
Back-iron density = flux per pole

2 x back-iron area
These formulas show that when redesigning a given core for a given number
of poles and one or more of the densities is too high or too low, the only way
to change the density is to change the flux per pole. The density will vary in
direct proportion to the change in the flux.
The formula for calculating flux per pole is:

22,500,000 x phase voltage x phases x circuits
Flux per pole =
frequency x turns per coil x coils x dist. fact x chord fact.
If the connection, circuits and span are not changed, the flux per pole will
vary inversely in proportion to the change in number of turns. As the turns
increase, the flux per pole decreases. As the turns decrease, the flux per pole
increases. Therefore, since the densities vary in direct proportion to a change
in flux, and the flux varies inversely as the number of turns change, the densi-
ties will vary inversely as the turns change.
original calculated densities x original calculated turns
New calculated densities =
new calculated turns

It is not necessary to calculate the new value of the flux per pole. Simply mul-
tiply the densities by the inverse ratio of the turns change. The output power
will vary by the square of the inverse ratio of the turns change.
Recalculated output = calculated output x

( original calculated turns
new calculated turns ) 2
For high densities, take the one furthest away from the recommended value
and add turns until a desirable value is reached. For low densities, start with
the one closest to the recommended value and reduce the turns. After arriving
at the proper number of turns, recalculate the other two densities and the rated
output power.
Sample Original nameplate data: 40 hp, 1775 rpm, 230/460 volts, 60 hertz, frame
Redesign 324T, 3 phase, dripproof.
1-11, connected 4 and 2 delta.
Core data (in inches): 48 slots, bore 7.75, core length 6, tooth width .235,
back iron 1.125 (refer to Figures A and B, Page 124).
Desired new rating: 60 hp, 1800 rpm, 230/460 volts, 60 hertz, 3 phase
Calculate turns by the output formula (Page 9).
T2 = T1x = 17 x = 13.9 turns per coil
nected 2 delta for 460 volts. From Table K, Page 118, the chord factor is .966.
From Table J, Page 117, the distribution factor is .958.

Flux per pole =
hertz x coils x turns per coil x chord fact x dist. fact.
22,500,000 x 460 x 3 x 2
= = 1,664,288 magnetic
60 x 48 x 14 x .966 x .958 lines of flux per pole
flux per pole

Back-iron density =

1,664,288
2 x 6 x 1.125 x .95 of flux per square inch

Air-gap density =
1.57 x 1,664,288 x 4
3.14 x 7.75 x 6 of flux per square inch

Tooth density =
1.57 x 1,664,288 x 4
6 x 48 x .235 x .95 of flux per square inch
The tooth density exceeds the recommended value for use with even a Class
H insulation system, so the motor must be weakened. To do this, it will be
necessary to increase the number of turns.
Table 18.1


centimeter.

From our discussion of flux densities on Pages 42 - 45, we know we can in-
crease the values in Table 18.1 by 20 percent when using a Class H insulation
system. Table 18.1 gives a value of 120,000; so 120,000 x 1.2 = 144,000.
To find the new turns, multiply the calculated turns for the redesign by the
calculated tooth density, divided by the desired maximum tooth density.
calculated density
Turns = calculated turnsx maximum suggested density
= 14 x 162,556 = 15.8
144,000
It will be necessary to use 16 turns.

original calculated turns
New calculated densities = original calculated densities x
new calculated turns
All densities will decrease by the ratio of 14 .

16
New back-iron density = 129,769 x 14 = 113,548 lines per square inch

16
New air-gap density = 71,546x 14 = 62,603 lines per square inch

16
New tooth density = 162,556 x 14 = 142,236 lines per square inch

16
Changing the turns changes the output power. Adding turns, as we did in this
case, reduces the output power.
Recalculated output = calculated output x ( original

new calculated turns )
calculated turns 2
Recalculated hp = 60x = 46 hp
T1
CM2 = CM1x T
2
From Table O, on Page 120, the circular mil area of #17 wire (AWG) is 2050.
CM1 = 2x2050 = 4100 circular mils
CM2 = 4100x 17 = 4356 circular mils

16
1-#18 and 2-#19 wire (AWG) = 1620 + (2 x 1290) = 4200 circular mils

We did not change poles, so the original ampere rating can be used to calcu-
late the new ampere rating, if it can be read from the nameplate.
new hp
New amperes = original amperes x original hp
If the nameplate is missing or the amperes are not legible, use the full-load
current table.
From Table F on Page 115, the full-load current of a 40 hp motor operating

on 460 volts is 52 amperes; and for a 50 hp motor, the full-load current is 65
amperes. The current for our new motor will be somewhere in between.
To figure the ampere rating for a motor with a non-standard output rating,
subtract the ampere rating of the nearest smaller rating from the ampere rating
of the nearest higher rating. Multiply this value by the difference between the
old output rating and the nearest lower standard rating, divided by the differ-
ence between the nearest higher and nearest lower output ratings, and add the
result of the current rating of the nearest lower output rating. In our case:
I = [(65 50) x (4650 -- 4060 )] + 50 = (

15 x 6 )
10 + 50 = 59 amperes
Thus, the full-load current for a motor rated 46 hp is 59 amperes at 460 volts.
Circular mils per ampere = phase amperes
For a delta connection, phase amperes equal 58 percent of line amperes. For a
Circular mils per ampere = 4200 x 2 = 245 circular mils per ampere
.58 x .59
Table 18.2
Pre-1960 Motors 430 550

The calculated wire is large enough to carry the full-load amperes of this mo-
tor with a Class F insulation system. The new winding data will thus be 16
turns per coil, 1-#18 and 2-#19 wire (AWG), span 1-11, connected 4 and 2
delta.

19 Determining The Proper Connection
Sometimes when a motor is received for repair the connection is so badly

damaged that no one can tell what it was, even though the rest of the winding
data is obtainable. In such circumstances, there are two ways of determining
what the connection should be for a single-speed motor. The most accurate
is to calculate the air-gap density. An easier but less accurate method is to
calculate the circular mils per ampere of the winding. (The latter is less reli-
able because manufacturers allow a much greater range for circular mils per
ampere than for air-gap densities.)
For example, take a 50 hp, 1800 rpm, 230/460 volt, 122/61 amps, 326T frame,
TEFC motor. The winding data is 48 slots and coils, 7 turns per coil, 2-#16
and 3-#17 wires, span 1-11. The bore diameter is 9 inches, and the core length
is 8 inches.
Table 19.1


centimeter.

Using the air-gap density method first, we see from Table 19.1 that the air-gap
density should be around 55,000 lines per square inch [8,525 lines per square
centimeter] for Todays motors. For a four-pole, dual-voltage, nine-lead
motor with even coil grouping, there is a choice of four connections: 1) 2 and
1Y; 2) 2 and 1 delta; 3) 4 and 2Y; and 4) 4 and 2 delta. Calculate the air-gap
density for a 2 and 1Y connection and use the ratio method for the other
connections.
Flux per pole =
hertz x coils x turns per coil x chord fact. x dist. fact.
22,500,000 x 265 x 3 x 1
Air-gap density =
3.14 x bore diam. x core length
1.57 x 958,774 x 4
3.14 x 9 x 8 of flux per square inch
For a 4 and 2Y connection:

26,619 x 2 = 53,238 magnetic lines of flux per square inch
For a 2 and 1 delta connection:
26,619 x 1.732 = 46,106 magnetic lines of flux per square inch
26,619 x 1.732 x 2 = 92,211 magnetic lines of flux per square inch
The 4 and 2Y connection gives the air-gap density closest to the 55,000 lines
per square inch value, so it is the connection to use. There is not much dif-
ference between the 4 and 2Y connection and the 2 and 1 delta connection.
Since the star connection is the strongest without being excessively high, it is
the connection to use.
Using the circular mils per ampere method, we could refer to Table 19.2 and
find that the value should be approximately 450 for Todays TEFC motor.
Table 19.2
Pre-1960 Motors 430 550


From Table O on Page 120, the circular mils of a #16 wire (AWG) are 2580,
and #17 wire (AWG) has 2050 circular mils. With two strands of #16 and
3 strands of #17, the circular mil area = (2 x 2580) + (3x2050) = 11,310
circular mils.
Circular mils per ampere = phase amperes
Phase amperes equal line amperes for star-connected motors, and 58 percent
of line amperes for delta-connected motors.
For a 2 and 1Y connection:

11,310 x 1
Circular mils per amp = = 185 circular mils per ampere
61
For a 4 and 2Y connection: 185 x 2 = 370 circular mils per ampere.

11,310 x 1
Circular mils per amp = = 320 circular mils per ampere
.58 x 61
For a 4 and 2 delta connection: 320 x 2 = 640 circular mils per ampere.
Again, the 4 and 2Y connection gives the figure closest to the recommended
450 circular mils per ampere value. Consequently, it would be the connection
to use.

20 Single-Phase Redesign
If no pole change is required, the procedures for redesigning single-phase

motors are similar to those used for polyphase motors. The major differ-
ence is that with single-phase redesigns each coil of each winding must be
consideredseparately.
The first step in a single-phase redesign is to find a conversion factor. To do

so, multiply the ratio of a voltage, output power and/or frequency change, as is
done in the Master Formula (see Page 29). This formula is:
E2
Conversion factor = E x x
1
where:
E = line voltage subscript 1 = original
hp = horsepower (or kilowatts) subscript 2 = new
F = frequency
Since the turns are usually different in each coil of each winding, the original
turns must be multiplied by the conversion factor and then rounded off to the
nearest whole number to obtain the new turns for each coil. If there are only a
few turns, the number of parallel circuits may be increased. Do not attempt to
change the spans.
Calculating If the output power is increased, the densities must be calculated. To do so,
Densities determine the effective turns per pole for the running winding by multiplying
the turns of each coil by its chord factor and adding all the results.
Effective turns per pole = (T1 x CF1) + (T2 x CF2) + (T3 x CF3) + etc.
The effective turns per pole are then used to calculate the flux per pole.
22,500,000 x volts x circuits

Flux per pole =
frequency x effective turns per pole x poles
The change in wire size can be based on the turn change for the outside coil of
each winding.

Sample Original nameplate data: 2 hp, 4 pole, 230 volts, 60 hertz, 1 phase.
Redesign Original winding data: run winding7-19-23-31 turns per coil, 2-#17 wire
(AWG), spans 1-3-5-7-9, connected 1 circuit; start winding19-27-40-20
turns per coil, 1-#17 wire (AWG), spans 1-4-6-8-10, connected 1 circuit.
Core data (in inches): 36 slots, bore 5, core length 2.875, tooth width .25,
back iron .75 (refer to Figures A and B, Page124).
Desired new rating: 3 hp, 4 pole, 208 volts, 60 hertz.

E2
Conversion factor= E x x
1
Conversion factor = 208 x x = .738

230

Run Winding
Span Original Turns Conversion Calculated Turns New Turns
Per Coil Factor Per Coil Per Coil
1-3 7 x .738 = 5.17 5

1-5 19 x .738 = 14.0 14
1-7 23 x .738 = 16.98 17
1-9 31 x .738 = 22.9 23
Start Winding
Span Original Turns Conversion Calculated Turns New Turns
Per Coil Factor Per Coil Per Coil
1-4 19 x .738 = 14.0 14

1-6 27 x .738 = 19.9 20
1-8 40 x .738 = 29.5 29
1-10 20 x .738 = 14.76 15
From Table 20.1, the chord factors for 9 slots per pole are:
1-3 = .342, 1-5 = .643, 1-7 = .866, 1-9 = .985
New run windings effective turns per pole:
= (T1 x CF1) + (T2 x CF2) + (T3 x CF3) + (T4 x CF4)
= (5 x .342) + (14 x .643) + (17 x .866) + (23 x .985)
= 1.71 + 9.002 + 14.722 + 22.655 = 48.089
Use 48.1 effective turns per pole.

Table 20.1
Chord Factor
SLOTS PER POLE
Coil
Span 24 22 20 18 16 15 12 11 10 9 8 6 4 3
1-25 1.000 .990 .951 .866

1-24 .998 .997 .972 .906
1-23 .991 1.000 .988 .940 .831
1-22 .981 .997 .997 .966 .882
1-21 .966 .990 1.000 .985 .924 .866
1-20 .947 .977 .997 .996 .957 .914
1-19 .924 .959 .988 1.000 .981 .951
1-18 .897 .937 .972 .996 .995 .978 .793
1-17 .866 .910 .951 .985 1.000 .995 .863 .756
1-16 .831 .878 .924 .966 .995 1.000 .924 .841 .707
1-15 .793 .841 .891 .940 .981 .995 .966 .910 .809 .643
1-14 .752 .801 .853 .906 .957 .978 .991 .960 .891 .766
1-13 .707 .756 .809 .866 .924 .951 1.000 .990 .951 .866 .707
1-12 .707 .760 .819 .882 .914 .991 1.000 .988 .940 .831
1-11 .707 .766 .831 .866 .966 .990 1.000 .985 .924
1-10 .707 .743 .809 .924 .960 .988 1.000 .981 .707
1- 9 .643 .707 .743 .866 .910 .951 .985 1.000 .866
1- 8 .634 .669 .793 .841 .891 .940 .981 .966
1- 7 .556 .588 .707 .756 .809 .866 .924 1.000 .707
1- 6 .500 .609 .655 .707 .766 .831 .966 .924
1- 5 .588 .643 .707 .866 1.000 .866
1- 4 .556 .707 .924 1.000
1- 3 .707 .866

( ) = Sin70 =.940
slots/pole
36/4
22,500,000 x volts x circuits

Flux per pole =
frequency x effective turns per pole x poles
22,500,000 x 208 x 1
60 x 48.1 x 4
of flux for each pole
flux per pole
Back-iron density =
405,405
2 x 2.875 x .75 x .95 of flux per square inch

Air-gap density =
1.57 x 405,405 x 4
3.14 x 5 x 2.875 of flux per square inch

Tooth density = core length x slots x tooth width x .95
1.57 x 405,405 x 4
2.875 x 36 x .25 x .95 of flux per square inch
The densities are reasonable, so the winding is acceptable.
To complete the redesign, we must calculate the new wire size for both the run
and start windings.
T1
CM2 = CM1 x
T2
From Table O, Page 120, the circular mil area of #17 wire (AWG) is 2050.
For the run winding:
31
23
1-#18 and 3-#19 wires (AWG) = 1620 + (3 x 1290) = 5490 circular mils
From Table H on Page 116, the full-load current for a three horsepower, single-
phase motor operating at 230 volts is 17 amperes. To find the full-load current
at a different voltage, multiply the reference full-load current by the reference
voltage divided by the rated voltage. In this example, 17 x 230 / 208 = 18.8.
The full-load current at 208 volts, therefore, is 18.8 amperes.
Circular mils per ampere = amperes
5490 x 1
=
18.8
= 292 circular mils per ampere
The calculated wire size is large enough to carry the full-load current of this
motor.

For the start winding:
20
15
2-#20 and 1-#21 wires (AWG) = (2 x 1020) + 812 = 2852 circular mils
The new winding data is: run winding5-14-17-23 turns per coil, 1-#18
and 3-#19 wires (AWG), spans 1-3-5-7-9, connected 1 circuit; start
winding14-20-29-15 turns per coil, 2-#20 and 1-#21 wires (AWG), spans
1-4-6-8-10, connected 1 circuit.

21 Calculation Of Secondary Voltage
Sometimes it is necessary to find the secondary voltage of a wound-rotor

motor because it is not shown on the nameplate. If both the stator and rotor
windings are good, this value can be determined from a simple test. With
the shaft locked to prevent rotation and the rotor circuit open, apply a voltage
(rated or lower) to the stator windings and measure the voltage across the slip
rings. The rotor voltage can then be calculated as follows:
EL
ER = EM x
EA
where:

ER = rated rotor voltage

EM = measured voltage across slip rings

EL = rated line voltage of stator windings

EA = voltage applied to stator windings
Suppose you apply 120 volts to a 440-volt winding and read 95 volts across
the rings. The rated secondary voltage is:
EL
ER = EM x
EA
440
ER = 95 x = 348 volts
120
Rotor If the winding data for both the stator and rotor are known, the rotor voltage
Volts By can be calculated with this formula:
Calculation TR x SR x CFR x NS x KR x ES
ER =
TS x SS x CFS x NR x KS
where:
1.73 if wye connected
E = voltage
K = {
1.0 if delta connected
T = turns per coil subscript R = rotor
S = slots subscript S = stator
CF = chord factor N = circuits

Sample 60 hp, 4 pole, 460 volts, frame 404 T, 60 hertz.
Calculation Stator data: 72 slots and coils, 9 turns per coil, span 1-16, connected 2 delta,
chord factor = .966 (see Table 21.1).
Rotor data: 48 slots and coils, 6 turns per coil, span 1-10, connected 2 Y,
chord factor = .924 (see Table 21.1).
TR x SR x CFR x NS x KR x ES
ER =
TS x SS x CFS x NR x KS
6 x 48 x .924 x 2 x 1.73 x 460

ER = = 339 volts
9 x 72 x .966 x 2 x 1
Table 21.1
Chord Factor
SLOTS PER POLE
Coil
Span 24 22 20 18 16 15 12 11 10 9 8 6 4 3
1-25 1.000 .990 .951 .866

1-24 .998 .997 .972 .906
1-23 .991 1.000 .988 .940 .831
1-22 .981 .997 .997 .966 .882
1-21 .966 .990 1.000 .985 .924 .866
1-20 .947 .977 .997 .996 .957 .914
1-19 .924 .959 .988 1.000 .981 .951
1-18 .897 .937 .972 .996 .995 .978 .793
1-17 .866 .910 .951 .985 1.000 .995 .863 .756
1-16 .831 .878 .924 .966 .995 1.000 .924 .841 .707
1-15 .793 .841 .891 .940 .981 .995 .966 .910 .809 .643
1-14 .752 .801 .853 .906 .957 .978 .991 .960 .891 .766
1-13 .707 .756 .809 .866 .924 .951 1.000 .990 .951 .866 .707
1-12 .707 .760 .819 .882 .914 .991 1.000 .988 .940 .831
1-11 .707 .766 .831 .866 .966 .990 1.000 .985 .924
1-10 .707 .743 .809 .924 .960 .988 1.000 .981 .707
1- 9 .643 .707 .743 .866 .910 .951 .985 1.000 .866
1- 8 .634 .669 .793 .841 .891 .940 .981 .966
1- 7 .556 .588 .707 .756 .809 .866 .924 1.000 .707
1- 6 .500 .609 .655 .707 .766 .831 .966 .924
1- 5 .588 .643 .707 .866 1.000 .866
1- 4 .556 .707 .924 1.000
1- 3 .707 .866

( ) = Sin70 =.940
slots/pole
36/4

Calculating The formula for calculating the turns in the rotor winding needed to produce a
A Rotor desired secondary voltage with a known stator winding is:
Winding TS x SS x CFS x NR x KS x ER
TR =
SR x CFR x NS x KR x ES
When using this formula, you must first necessary assume a connection and
span for the rotor winding. Use 1Y if possible. The span and connection can
later be changed if the turns do not calculate to be a whole number.
Sample As an example, suppose a secondary voltage of 350 is needed for a 50 hp,

Redesign 1200 rpm, 220/440 volt, wound-rotor motor. The stator winding is 72 slots
and coils, 14 turns per coil, span 1-11, chord factor = .966 (see Table 21.1),
connected 6 and 3 delta. The rotor has 90 slots. Assuming a 1 delta connec-
tion and a span of 1-16 (full pitch), the rotor turns would calculate to be:
TS x SS x CFS x NR x KS x ER
TR =
SR x CFR x NS x KR x ES
6 x 48 x .924 x 2 x 1.73 x 460

TR = = 2.87 turns per coil
9 x 72 x .966 x 2 x 1
Changing the secondary connection to 3 delta, the turns per coil become:
TR = 2.87 x 3 = 8.61 turns per coil
Nine turns can be used if the span is shortened to a chord factor of:
8.61
CF = 1 x = .957 (1 = present rotor CF)
9
From Table 21.1, the closest possible chord factor is .951 for a 1-13 span.
Changing to a 1-13 span changes the calculated turns to:
1
TR = 8.61 x .951 = 9.05 turns per coil
The actual secondary voltage would then be:

9.05
ER = x 350 = 352 volts
9
The allowable tolerance between the nameplate secondary voltage and the
actual secondary voltage is 10 percent. Thus, the new rotor winding would be
9 turns per coil, span 1-13, connected 3 delta.
See Table 21.2 for suggested secondary volts.

Table 21.2

Secondary Data For Wound-Rotor Motors
Maximum Maximum
Secondary Secondary, Secondary Secondary,
Hp Volts* Amperes Hp Volts* Amperes
1 90 6 25 220 60
1.5 110 7.3 30 240 65
2 120 8.4 40 315 60
3 145 10 50 350 67
5 140 19 60 375 74
7.5 165 23 75 385 90
10 195 26.5 100 360 130
15 240 32.5 125 385 150
20 265 38 150 380 185
Ref: NEMA Standards MG1-10.35 (1987)

*Tolerance - plus or minus 10 percent

22 Determining Three-Phase Coil Grouping
The following method can be used to determine the coil grouping for a three-
phase, lap winding with two coil sides per slot. The first step is to determine
the number of groups. This is done by multiplying the number of poles times
the number of phases.
1) groups = poles x phases = poles x 3
Next, determine the average number of coils per group by dividing the number
of slots by the number of groups. Any remainder should be put in the form
of a fraction, because both the numerator (B) and the denominator (C) will be
used later on.
slots
2) Average coils per group = groups = A B
C
If the grouping is even, A will be a whole number and will be the number
of coils in each group (see Example 1). With odd grouping some groups will
have A coils per group, and the remainder will have A + 1 coils per group.
C (the denominator in the fraction in Formula 2) is the number of coils in
each section, and the number of poles you must go through to get a repeatable
pattern. The number of repeatable patterns in the entire motor equals poles
divided by C.
poles
3) Repeatable patterns = = RP
C
This represents the maximum number of parallel circuits. The number of
groups with A coils per group will equal three times the repeatable patterns
(RP), times (C B) from Formula 2.
4) Groups with A coils = 3 x RP x (C B) = X
The number of groups with A + 1 coils per group will equal three times the
repeatable groups (RP) times B from Formula 2.
5) Groups with A + 1 coils = 3 x RP x B = Y

To be sure no error has been made thus far, multiply the groups with A coils
(X) by A and the groups with A + 1 coils (Y) by A + 1 and add the two
products. The sum must equal the number of slots.
6) Slots = (X x A) + [Y x (A + 1)]
X
The number of groups with A coils in each section* equals C x groups.
*A section is the number of coil groups before the pattern repeats.
Y
The number of groups with A +1 coils in each sectionequals C x groups.
X
7) Groups with A coils per section = C x groups
Y
8) Groups with A + 1 coils per section = C x groups
If C does not equal three or a multiple of three (6, 9, 12, etc.), arrange the
groups in any manner you desire and repeat the sequence for all sections in
the motor. After three sections, you should arrive at a repeatable pattern (see
Example 2).
If C equals three or a multiple of three, each section will have to be rear-

ranged to get the total coils in each phase to be equal. Again, after three
sections, you will arrive at a repeatable pattern (see Example 3).
Once you have decided upon your group layout, check it to be sure it is
balanced. Now determine how many pole-phase groups you will have in
series by dividing the number of poles by the number of parallel circuits.
poles
9) Groups in series = circuits
The next step is to decide whether you want to use a short jumper (1-4) or a
long jumper (1-7). Write down the grouping sequence in a, b, and c
columns for the number of groups in series. For a short jumper, take the pole-
phase groups in sequence. For a long jumper, take alternate pole-phase groups
per column.
Now add the series coils for each circuit of each phase. The total of each
column must be the same. If not, revise the sequence, change the jumper, or
both (see Examples 2 and 3).

Example 1 Number of slots: 60 Number of poles: 4
From Formula 1:
Groups = poles x 3 = 4 x 3 = 12
From Formula 2:
slots
Average coils per group series = groups = 5
This motor has even coil grouping and would be wound with 12 groups of five
coils.
From Formula 1:
From Formula 2:
slots
Avg. coils per group series = groups = 72 = 2 x 12 = 2 x 2
30 30 5
Therefore A = 2, B = 2, C = 5
From Formula 3:
poles
Repeatable patterns = = 10 = 2 = RP
C 5
Thus, the maximum number of parallel circuits is two. Some groups will have
two coils per group (A = 2), while the remainder will have three coils per
group (A + 1 = 3).
From Formula 4:
Groups with two coils = 3 x RP x (C B)
= 3 x 2 x (5 2)
= 3 x 2 x 3
= 18 = X
From Formula 5:
Groups with three coils = 3 x RP x B
= 3 x 2 x 2
= 12 = Y
The grouping will be 18 groups of 2 and 12 groups of 3.

Use Formula 6 to check your calculations thus far.
Slots = (X x A) + [Y x (A + 1)]
= (18 x 2) + (12 x 3)
= 36 + 36 = 72
From Formulas 7 and 8:

X
(7) Groups with two coils per section = C x groups = 5 x 18 = 3
30
Y
(8) Groups with three coils per section = C x groups = 5 x 12 = 2
30
Thus, every section of five groups will have three groups of two coils, and two
groups of three coils. You can arrange the section any way you wish (e.g.,
22233 or 23232 or 33222), but all sections must repeat in the same manner.
As an example, well use 23232. After first dividing the section into three
groups per pole, we expand from this until we get a repeatable pattern (e.g.,
232, 322, 323, 223, 232), and then repeat it once more.
Lets say we want a two-circuit connection.
From Formula 9:
poles
Groups in series = circuits = 10 = 5
2
For a short jumper, list the coils per group in columns for each phase and add
up the columns. Each of the three columns must have the same total.
We only need to list five poles, because poles six through 10 are exactly the
same as poles one through five.
2 3 2
3 2 2
3 2 3
2 2 3
2 3 2
12 12 12
Each column has the same total, so a short jumper will work.
For a long jumper, list all 30 pole-phase groups (since the grouping in each
circuit is not the same), with the odd number poles and the even numbered
poles in different columns.

2 3 2 3 2 2
3 2 3 2 2 3
2 3 2 2 3 2
3 2 2 3 2 3
2 2 3 2 3 2
12 12 12 12 12 12
A long jumper will also work with this grouping.
From Formula 1:
From Formula 2:
slots
Avg. coils per group series = groups = 60 = 3 x 6 = 3 x 1
18 18 3
Therefore, A = 3, B = 1, C = 3
From Formula 3:
poles
Repeatable patterns = = 6 = 2 = RP
C 3
The maximum number of parallel circuits, therefore, is two. Some coil groups
will have three coils per group (A = 3), while the remainder will have four
coils per group (A + 1 = 4).
From Formula 4:
Groups with three coils = 3 x RP x (C B) = 3 x 2 x (3 1) = 3 x 2 x 2 = 12 = X
From Formula 5:
Groups with four coils = 3 x RP x B = 3 x 2 x 1 = 6 = Y

The grouping will be 12 groups of three and six groups of four.
Use Formula 6 to check your calculations thus far.
Slots = (X x A) + [Y x (A + 1)] = (12 x 3) + (6 x 4) = 36 + 24 = 60
From Formulas 7 and 8:
X
(7) Groups with three coils per section = C x groups = 3 x 12 = 2
18
Y
(8) Groups with four coils per section = C x = groups = 3 x 6 = 1
18
Thus, every section of three groups will have two groups of three coils and
one group of four coils. The coil arrangement cannot be the same in all sec-
tions. If it were the same, say 433, A phase would have four coils in every
group, while B and C phases would have three coils in every group.
The sections must be arranged so that the phases, and each circuit within the
phases, have the same number of coils. Thus, the groups with four coils must
move from A phase to B phase to C phase. The grouping therefore
becomes 433, 343, 334 and repeats one more time.
If you want a two-circuit connection, begin with Formula 9:

poles
Groups in series = circuits = 6 = 3
2
For a short jumper, list the coils per group in columns for each phase and add
up the columns. As before, each of the three columns must have the same
total. Since poles four through six are exactly the same as poles one through
three, only three poles need to be listed.
4 3 3
3 4 3
3 3 4
10 10 10
The columns have the same total, so this grouping will work with a short
jumper.

For use with a long jumper, list all six poles in two different circuitsthe odd
number poles in one circuit, the even number poles in the other.
4 3 3 3 4 3
3 3 4 4 3 3
3 4 3 3 3 4
10 10 10 10 10 10
A long jumper will also work with this grouping.

Appendix
Table A
Parallel Circuits For Two-Winding Motors
This table shows the minimum number of poles connected in series in each leg of a parallel circuit.
High-Speed Winding
Speed Ratio Adjacent Pole (1-4) Skip Pole (1-7)
3/1, 5/1, 7/1, etc. Impossible Impossible
2/1, 4/1, 6/1, etc. 2 Impossible
3/2, 5/2, 7/2, etc. 4 2
4/3, 8/3, 10/3, etc. 6 3
5/3, 7/3, 11/3, etc. 3 3
5/4, 7/4, 9/4, etc. 8 4
6/5, 8/5, 12/5, etc. 10 5
7/5, 9/5, 11/5, etc. 5 5
Low-Speed Winding
Speed Ratio Adjacent pole (1-4) Skip Pole (1-7)
2/1 4 2
3/1 3 3
3/2 6 3
4/1, 4/3 8 4
5/1, 5/3 5 5
5/2, 5/4 10 5
6/1, 6/5 12 6
7/1, 7/3, 7/5 7 7
7/2, 7/4, 7/6 14 7
Table B
Two-Speed, One Winding Motor Connections
Connections* Hp Ratio
Type High/Low Speed
High Low
Constant Hp 1D 2Y 1/1
Constant torque 2Y 1D 2/1
Variable torque 2Y 1Y 4/1
* The connections may be multiples of those shown in the table. The horsepower ratios in
TableB are for motors manufactured in North America. Output ratios of motors manufac-
tured in other parts of the world are much closer.

Table C
Maximum Rotor Diameters*
Inches Millimeters
Poles
60 HZ 50 HZ 25 HZ 60 HZ 50 HZ 25 HZ
2 10.6 12.7 25.5 269 323 648
4 21.2 25.5 50.9 538 648 1293
6 31.8 38.2 808 970
8 42.4 50.9 1077 1293
* Table is based on a peripheral speed of 10,000 ft/min [3,048 m/min].
Table D


centimeter.

Table E
2 1, 2, 3, 4 6, 12, 18, 24 2, -4, -10

4 1, 2, 3, 4, 5, 6 12, 24, 48, 60 4, -8, -20
6 1, 2, 4, 5, 7, 8 18, 36, 54, 72 6, -12, -30
8 1, 2, 6, 7, 9, 10 24, 48, 72 8, -16, -40
10 1, 2, 8, 9, 11, 12 30, 60, 90 10, -20, -50
12 1, 2, 10, 11, 13, 14 36, 72 12, -24, -60
14 1, 2, 12, 13, 15, 16 42 14, -28
16 1, 2, 14, 15, 17, 18 48 16, -32
18 1, 2, 16, 17, 19, 20 54 18, -36
20 1, 2, 18, 19, 21, 22 60 20, -40
24 1, 2, 22, 23, 25, 26 72 24, -48
32 1, 2, 30, 31, 33, 34 96 32, -64
36 1, 2, 34, 35, 37, 38 108 36, -72
48 1, 2, 46, 47, 49, 50 144 48, -96
Table F
Motor Full-Load Currents
Three-Phase AC Induction TypeSquirrel Cage And Wound-Rotor
HP 115V 200V 230V 460V 575V 2300V 4000V

.5 4 2.3 2 1 .8
.75 5.6 3.2 2.8 1.4 1.1
1 7.2 4.15 3.6 1.8 1.4
1.5 10.4 6 5.2 2.6 2.1
2 13.6 7.8 6.8 3.4 2.7
3 11 9.6 4.8 3.9
5 17.5 15.2 7.6 6.1
7.5 25 22 11 9
10 32 28 14 11
15 48 42 21 17
20 62 54 27 22
25 78 68 34 27
30 92 80 40 32
40 120 104 52 41
50 150 130 65 52
60 177 154 77 62 16 8.8
75 221 192 96 77 20 11
100 285 248 124 99 26 14.3
125 358 312 156 125 31 18
150 415 360 180 144 37 20.7
200 550 480 240 192 49 27.6
Over 200 HP
Approx. amps / hp 2.75 2.4 1.2 .96 .24 .14

Table G
Three-Phase Synchronous Motors
Unity Power Factor
HP 460V 575V 2300V 4000V

100 100 80 20 11.5
125 125 100 25 14.4
150 150 120 30 17.2
200 200 160 40 23

250 250 200 50 28.7
300 300 240 60 34.5
350 353 282 70.5 40.5

400 403 322 80.5 46.3
500 500 400 100 57.5
600 600 480 120 69

700 705 564 141 81
800 805 644 161 92.6
900 905 724 181 104

1000 960 768 192 110
Table H
Full-Load Currents
Single-Phase Motors
HP 115V 200V 230V
1
/6 4.4 2.5 2.2
1
/4 5.8 3.3 2.9
1
/3 7.2 4.1 3.6
1
/2 9.8 5.6 4.9
3
/4 13.8 7.9 6.9
1 16 9.2 8
1 /2
1
20 11.5 10
2 24 13.8 12
3 34 19.6 17
5 56 32.2 28
71/2 80 46 40
20 100 57.5 50


Table I
Pre-1960 Motors 430 550

phase amperes
For a star connection, phase amperes = line amperes
For a delta connection, phase amperes = line amperes x .58
Table J

1 1.000 1.000 1.0
2 .966 .837 1.0
3 .960 .831 1.0
4 .958 .829 1.0
5 .957 .828 1.0
6 or more .956 .827 1.0

180
A =
slots per pole
A x B
Sin 2 ( ) A x B
Sin
2 ( )
DF =
slots
DF = B =
poles x phases
A
B x Sin
2
( ) 30
2 x B x Sin
B
( ) (Always calculate B
for wound poles.)
Example: Standard Winding

54 180 54 = 2.25
54 slots, 8 poles; slots per pole = = 6.75 A = = 26.7; B =
8 6.75 8 x 3
Sin
(
26.7x2.25 )
2 Sin (30) .5
( )
DF = =
2.25 Sin (13.35) =
2.25x.231 = .962
2.25Sin 26.7
2
Example: Consequent Pole Winding

36 180 36 = 3
36 slots, 8 poles; slots per pole = = 4.5 (wound poles = 4) A
= = 40;
4.5 B =
4x3
8
(
Sin
40x3
2 ) =
Sin (60) .866
( )
DF =
=
6x Sin (10) 6x.174
= .831
2x3Sin 30
3


Table K
Chord Factor
SLOTS PER POLE
Coil
Span 24 22 20 18 16 15 12 11 10 9 8 6 4 3
1-25 1.000 .990 .951 .866

1-24 .998 .997 .972 .906
1-23 .991 1.000 .988 .940 .831
1-22 .981 .997 .997 .966 .882
1-21 .966 .990 1.000 .985 .924 .866
1-20 .947 .977 .997 .996 .957 .914
1-19 .924 .959 .988 1.000 .981 .951
1-18 .897 .937 .972 .996 .995 .978 .793
1-17 .866 .910 .951 .985 1.000 .995 .863 .756
1-16 .831 .878 .924 .966 .995 1.000 .924 .841 .707
1-15 .793 .841 .891 .940 .981 .995 .966 .910 .809 .643
1-14 .752 .801 .853 .906 .957 .978 .991 .960 .891 .766
1-13 .707 .756 .809 .866 .924 .951 1.000 .990 .951 .866 .707
1-12 .707 .760 .819 .882 .914 .991 1.000 .988 .940 .831
1-11 .707 .766 .831 .866 .966 .990 1.000 .985 .924
1-10 .707 .743 .809 .924 .960 .988 1.000 .981 .707
1- 9 .643 .707 .743 .866 .910 .951 .985 1.000 .866
1- 8 .634 .669 .793 .841 .891 .940 .981 .966
1- 7 .556 .588 .707 .756 .809 .866 .924 1.000 .707
1- 6 .500 .609 .655 .707 .766 .831 .966 .924
1- 5 .588 .643 .707 .866 1.000 .866
1- 4 .556 .707 .924 1.000
1- 3 .707 .866

( ) = Sin70 =.940
slots/pole
36/4

Table L T
Radius Of Rectangular Wires W
Radius For Specific Width (Inches)

Thickness - Inches
.189 - .750 up to .188 incl.
0.688 to 0.439 incl. .094
0.438 to 0.226 incl. .063
0.225 to 0.166 incl .047 .047
0.165 to 0.126 inc. .031 .031
0.125 to 0.073 incl. .031 .016
0.072 to 0.051 incl. Rounded Edge .016
0.050 and under Rounded Edge Rounded Edge
TABLE M TABLE N
Radius Of Square Wires Radius Factor
Thickness (Inches) Radius (Inches) Radius (Inches) Radius Factor (Sq. Mils)
0.438 to 0.226 incl .062 .012 124
0.225 to 0.166 incl .047 .016 210
0.165 to 0.126 incl .031 .031 838
0.125 to 0.073 incl .016 .047 1886
0.072 to 0.050 incl .012 .063 3353
.094 7544
Tables courtesy of Phelps Dodge Magnet Wire Corp.

Table O
Round Magnet Wire Data
Nominal Diameters And Cross-Sectional Areas
BARE WIRE CROSS-SECTIONAL BARE WIRE CROSS-SECTIONAL

DIAMETER WIRE GAGE * AREA DIAMETER WIRE GAGE * AREA
Inches mm AWG SWG Metric Cir Mils mm2 Inches mm AWG SWG Metric Cir Mils mm2
.3066 7.788 0.5 94000 47.632 .1144 2.906 9 13090 6.631
.3000 7.620 1 90000 45.604 .1102 2.800 2.8 12150 6.158
.2953 7.500 7.5 87190 44.179 .1080 2.743 9.5 11660 5.910
.2893 7.348 1 83690 42.409 .1043 2.650 2.65 10880 5.515
.2795 7.100 7.1 78140 39.592 .1040 2.642 12 10820 5.481
.2760 7.010 2 76180 38.599 .1019 2.588 10 10380 5.261
.2730 6.934 1.5 74530 37.764 .0984 2.500 2.5 9690 4.909
.2638 6.700 6.7 69580 35.257 .0962 2.443 10.5 9250 4.689
.2576 6.543 2 66360 33.624 .0929 2.360 2.36 8630 4.374
.2520 6.401 3 63500 32.178 .0920 2.337 13 8460 4.289
.2480 6.300 6.3 61520 31.173 .0907 2.304 11 8230 4.168
.2431 6.175 2.5 59100 29.945 .0882 2.240 2.24 7780 3.941
.2362 6.000 6.0 55800 28.274 .0856 2.174 11.5 7330 3.713
.2320 5.893 4 53820 27.273 .0835 2.120 2.12 6970 3.536
.2294 5.827 3 52620 26.665 .0808 2.052 12 6530 3.308
.2205 5.600 5.6 48610 24.630 .0800 2.032 14 6400 3.243
.2165 5.499 3.5 46870 23.751 .0787 2.000 2.0 6200 3.142
.2120 5.385 5 44940 22.774 .0763 1.938 12.5 5820 2.950
.2087 5.300 5.3 43540 22.062 .0748 1.900 1.9 5600 2.835
.2043 5.189 4 41740 21.149 .0720 1.829 13 15 5180 2.627
.1969 5.000 5.0 38750 19.635 .0709 1.800 1.8 5020 2.545
.1928 4.897 4.5 37170 18.835 .0679 1.725 13.5 4610 2.336
.1920 4.877 6 36860 18.679 .0669 1.700 1.7 4480 2.270
.1870 4.750 4.75 34970 17.721 .0641 1.628 14 4110 2.082
.1819 4.620 5 33090 16.766 .0640 1.626 16 4100 2.075
.1772 4.500 4.5 31390 15.904 .0630 1.600 1.6 3970 2.011
.1760 4.470 7 30980 15.696 .0605 1.537 14.5 3660 1.855
.1717 4.361 5.5 29480 14.938 .0591 1.500 1.5 3490 1.767
.1673 4.250 4.25 28000 14.186 .0571 1.450 15 3260 1.652
.1620 4.115 6 26240 13.298 .0560 1.422 17 3140 1.589
.1600 4.064 8 25600 12.972 .0551 1.400 1.4 3040 1.539
.1575 4.000 4.0 24800 12.566 .0539 1.369 15.5 2910 1.472
.1529 3.884 6.5 23380 11.846 .0520 1.320 1.32 2700 1.368
.1476 3.750 3.75 21800 11.045 .0508 1.290 16 2580 1.308
.1443 3.665 7 20820 10.551 .0492 1.250 1.25 2420 1.227
.1440 3.658 9 20740 10.507 .0480 1.219 16.5 18 2300 1.167
.1398 3.550 3.55 19530 9.898 .0465 1.180 1.18 2160 1.094
.1362 3.459 7.5 18550 9.400 .0453 1.151 17 2050 1.040
.1319 3.350 3.35 17390 8.814 .0441 1.120 1.12 1940 .985
.1285 3.264 8 16510 8.367 .0427 1.085 17.5 1820 .924
.1280 3.251 10 16380 8.302 .0417 1.060 1.06 1740 .882
.1240 3.150 3.15 15380 7.793 .0403 1.024 18 1620 .823
.1213 3.081 8.5 14710 7.456 .0400 1.016 19 1600 .811
.1181 3.000 3.0 13950 7.069 .0394 1.000 1.0 1550 .785
.1160 2.946 11 13460 6.818 .0380 0.965 18.5 1440 .732
* Wire Gage Abbreviations: AWG is an abbreviation for American Wire Gage; SWG is an abbreviation for
(British) Standard Wire Gage. Square Inches x 1.273 x 106 = circular mils.

Round Magnet Wire DataContinued
Nominal Diameters And Cross-Sectional Areas
BARE WIRE CROSS-SECTIONAL BARE WIRE CROSS-SECTIONAL

DIAMETER WIRE GAGE * AREA DIAMETER WIRE GAGE * AREA
Inches mm AWG SWG Metric Cir Mils mm2 Inches mm AWG SWG Metric Cir Mils mm2
.0374 0.950 .95 1400 .709 .0140 0.355 .355 195 .0990
.0360 0.914 20 1300 .657 .0136 0.345 29 185 .0937
.0359 0.912 19 1290 .653 .0134 0.340 27.5 180 .0910
.0354 0.900 .9 1260 .636 .0132 0.335 .335 174 .0881
.0339 0.861 19.5 1150 .582 .0126 0.320 28 159 .0804
.0335 0.850 .85 1120 .567 .0124 0.315 30 .315 154 .0779
.0320 0.813 20 21 1020 .519 .0119 0.302 28.5 142 .0718
.0315 0.800 .8 992 .503 .0118 0.300 .3 140 .0707
.0302 0.767 20.5 912 .462 .0116 0.295 31 135 .0682
.0295 0.750 .75 872 .442 .0113 0.287 29 128 .0647
.0285 0.724 21 812 .412 .0110 0.280 .28 122 .0616
.0280 0.711 22 784 .397 .0108 0.274 32 117 .0591
.0280 0.710 .71 781 .396 .0106 0.269 29.5 112 .0569
.0269 0.683 21.5 724 .367 .0104 0.265 .265 109 .0552
.0264 0.670 .67 696 .353 .0100 0.254 30 33 100 .0507
.0253 0.643 22 640 .324 .0098 0.250 .25 96.9 .0491
.0248 0.630 .63 615 .312 .0095 0.241 30.5 90.3 .0457
.0240 0.610 23 576 .292 .0093 0.236 .236 86.3 .0437
.0239 0.607 22.5 571 .289 .0092 0.234 34 84.6 .0429
.0236 0.600 .6 558 .283 .0089 0.226 31 79.2 .0401
.0226 0.574 23 511 .259 .0088 0.224 .224 77.8 .0394
.0220 0.560 .56 486 .246 .0084 0.213 35 70.6 .0358
.0220 0.559 24 484 .245 .0083 0.212 .212 69.7 .0353
.0213 0.541 23.5 454 .230 .0080 0.203 32 64.0 .0324
.0209 0.530 .53 435 .221 .0079 0.200 .2 62.0 .0314
.0201 0.511 24 404 .205 .0076 0.193 36 57.8 .0293
.0200 0.508 25 400 .203 .0075 0.190 .19 56.0 .0284
.0197 0.500 .5 388 .196 .0071 0.180 33 .18 50.4 .0254
.0190 0.483 24.5 361 .183 .0068 0.173 37 46.2 .0234
.0187 0.475 .475 350 .177 .0067 0.170 .17 44.8 .0227
.0180 0.457 26 324 .164 .0063 0.160 34 .16 39.7 .0201
.0179 0.455 25 320 .162 .0060 0.152 38 36.0 .0182
.0177 0.450 .45 314 .159 .0059 0.150 .15 34.9 .0177
.0169 0.429 25.5 286 .145 .0056 0.142 35 31.4 .0159
.0167 0.425 .425 280 .142 .0055 0.140 .14 30.4 .0154
.0164 0.417 27 269 .136 .0052 0.132 39 .132 27.0 .0137
.0159 0.404 26 253 .128 .0050 0.127 36 25.0 .0127
.0157 0.400 .4 248 .126 .0049 0.125 .125 24.2 .0123
.0150 0.381 26.5 225 .114 .0048 0.122 40 23.0 .0117
.0148 0.376 28 219 .111
.0148 0.375 .375 218 .110
.0142 0.361 27 202 .102
* Wire Gage Abbreviations: AWG is an abbreviation for American Wire Gage; SWG is an abbreviation for
(British) Standard Wire Gage. Square Inches x 1.273 x 106 = circular mils.

Table P
Coil grouPing for Three-Phase windingsadjaCenT Pole ConneCTion (1-4)

number of poles
slots 2 4 6 8 10 12
6 groups of 2 12 groups of 2
12 222 111
1,2 cir 1,2,4 cir
6 groups of 3 6 groups of 1 18 groups of 1
6 groups of 2
18 333 121,212 111
1,2 cir 1,2 cir 1,2,3,6 cir
6 groups of 4 12 groups of 2 12 groups of 1 24 groups of 1
6 groups of 2
24 444 222 211,121,112 111
1,2 cir 1,2,4 cir 1,2 cir 1,2,4,8 cir
6 groups of 5 6 groups of 2 6 groups of 1 18 groups of 1 30 groups of 1
6 groups of 3 12 groups of 2 6 groups 2
30 555 232,323 122,212,221 211,121,112,111 111
1,2 cir 1,2 cir 1,2 cir 1,2 cir 1,2,5,10 cir
6 groups of 6 12 groups of 3 18 groups of 2 12 groups of 1 24 groups of 1 36 groups of 1
36 666 333 222 121,212 211,112,111,121,111 111
1,2 cir 1,2,4 cir 1,2,3,6 cir 1,2,4 cir 1,2 cir 1,2,3,4,6,12 cir
42 777 343,434 322,232,223 122,212,221,222 121,211,212,112,121 211,111,121,111,112,111
1,2 cir 1,2 cir 1,2 cir 1,2 cir 1,2 cir 1,2 cir
3 groups of 7 3 groups 3 9 groups of 2 3 groups of 1 15 groups of 1
45 878,787 444,344,434,443 323,232 222,222,212,222, 212,121
222,122,222,221
1 cir 1 cir 1,2,3 cir 1 cir 1,2,5 cir
48 888 444 233,323,332 222 212,122,121,221,212 211,121,112
1,2 cir 1,2,4 cir 1,2 cir 1,2,4,8 cir 1,2 cir 1,2,4 cir
54 999 454,545 333 322,232,223,222 122,221,222,212, 121,212
222
1,2 cir 1,2 cir 1,2,3,6 cir 1,2 cir 1,2 cir 1,2,3,6 cir
60 10 10 10 555 433,343,334 232,323 222 122,212,221
1,2 cir 1,2,4 cir 1,2 cir 1,2,4 cir 1,2,5,10 cir 1,2,4 cir
12 groups of 3
72 12 12 12 666 444 333 232,322,323,223, 222
232
1,2 cir 1,2,4 cir 1,2,3,6 cir 1,2,4,8 cir 1,2 cir 1,2,3,4,6,12 cir
84 14 14 14 777 455,545,554 343,434 233,332,333,323, 322,232,223
333
1,2 cir 1,2,4 cir 1,2 cir 1,2,4 cir 1,2 cir 1,2,4 cir
90 15 15 15 787,878 555 344,434,443,444 333 232,323
1,2 cir 1,2 cir 1,2,3,6 cir 1,2 cir 1,2,5,10 cir 1,2,3,6 cir
96 16 16 16 888 655,565,556 444 433,334,333,343,333 233,323,332
1,2, cir 1,2,4 cir 1,2 cir 1,2,4,8 cir 1,2 cir 1,2,4 cir
108 18 18 18 999 666 454,545 434,344,343,443,434 333
1,2 cir 1,2,4 cir 1,2,3,6 cir 1,2,4 cir 1,2 cir 1,2,3,4,6,12 cir
120 20 20 20 10 10 10 677,767,776 555 444 433,343,334
1,2 cir 1,2,4 cir 1,2 cir 1,2,4,8 cir 1,2,5,10 cir 1,2,4 cir

Table PContinued
Coil grouPing for Three-Phase windingsadjaCenT Pole ConneCTion (1-4)ConT.

number of poles
slots 14 16 18 20 22 24
42 groups of 1
42 111
1,2,7,14 cir
45
6 groups of 2
48 211,111,121,111,112,111, 111
111
1,2 cir 1,2,4,8,16 cir
30 groups of 1 42 groups of 1 54 groups 1
54 211,211,121,121,112, 211,111,112,111,111,121, 111
112,111 111,111
1,2 cir 1,2 cir 1,2,3,6,9,18 cir
60 121,212,112,121,211, 211,121,112,111 211,111,111,121,111,111, 111
212,121 112,111,111
1,2 cir 1,2,4 cir 1,2 cir 1,2,4,5,10,20 cir
72 122,122,212,212,221, 121,212 211,121,112 211,112,111,121,111 211,111,111,112,111,111, 111
221,222 111,121,111,111,111
1,2 cir 1,2,4,8 cir 1,2,3,6 cir 1,2,4 cir 1,2 cir 1,2,3,4,6,8,12,24 cir
84 222 122,212,221,222 221,221,212,212,122, 121,211,212,112,121 211,121,112,112,111,211, 211,111,121,111,112,111
122,112,121,211 121,121,112,111,211
1,2,7,14 cir 1,2,4 cir 1,2 cir 1,2,4 cir 1,2 cir 1,2,4 cir
90 322,222,232,222,223, 122,222,221,222,222,212, 122,212,221 121,212 121,211,121,211,212,111, 211,121,112,111
222,222 222,222 212,112,121,112,121
1,2 cir 1,2 cir 1,2,3,6 cir 1,2,5,10 cir 1,2 cir 1,2,3,6 cir
96 322,322,232,232,223,223, 222 122,221,222,212,221,222, 212,122,121,221,212 121,212,121,211,212,121, 211,121,112
222 122,212,222 212,112,121,212,121
1,2 cir 1,2,4,8,16 cir 1,2 cir 1,2,4 cir 1,2 cir 1,2,4,8 cir
108 323,232,332,323,233,232, 322,232,223,222 222 122,221,222,212,222 212,122,212,122,121,222, 121,212
323 121,221,212,221,212
1,2 cir 1,2,4 cir 1,2,3,6,9,18 cir 1,2,4 cir 1,2 cir 1,2,3,4,6,12 cir
120 233,333,323,333, 232,323 322,223,222,232,223,222, 222 222,122,212,222,221,222, 122,212,221
332,333,333 322,232,222 122,222,212,221,222
1,2, cir 1,2,4,8 cir 1,2 cir 1,2,4,5,10,20 cir 1,2 cir 1,2,4,8 cir

table pContinued
Coil grouping for three-phase windingsskip pole ConneCtion (1-7)

number of poles
slots 4 6 8 10 12 14
12 groups of 1
12 111
1,2,4 cir
6 groups of 2
18 121,212,212,121 111
1,2 cir 1,2,3,6 cir
6 groups of 2
24 222 211,121,112 111
1,2,4 cir 1,2 cir 1,2,4,8 cir
30 232,323,323,232 122,212,221 211,121,112,111,111,211, 111
121,112
1,2 cir 1,2 cir 1,2 cir 1,2,5,10 cir
12 groups of 2 6 groups of 2 111
36 333 222 121,212,212,121 211,112,111,121,111
1,2,4 cir 1,2,3,6 cir 1,2,4 cir 1,2 cir 1,2,3,4,6,12 cir
42 343,434,434,343 322,232,223 122,212,221,222,222,122, 121,211,212,112,121 211,111,121,111,112,111, 111
212,221 111,211, 111,121,111,112
1,2 cir 1,2 cir 1,2 cir 1,2 cir 1,2 cir 1,2,7,14 cir
45 444,344,434,443 323,232 222,222,212,222 212,121,222,122,222,221
1 cir 1 cir 1,2 cir 1 cir
48 444 233,323,332 222 212,122,121,221,212 211,121,112 211,111,121,111,112,111,
111
1,2,4 cir 1,2 cir 1,2,4,8 cir 1,2 cir 1,2,4 cir 1,2 cir
54 454,545,545,454 333 322,232,223,222,222,322, 122,221,222,212,222 122,212,221 211,211,121,121,112,112,
232,223 111
1,2 cir 1,2,3,6 cir 1,2 cir 1,2 cir 1,2,4 cir 1,2 cir
60 555 433,343,334 232,323,323,232 222 122,212,221 121,212,112,121,211,212,
121
1,2,4 cir 1,2 cir 1,2,4 cir 1,2,5,10 cir 1,2,4 cir 1,2 cir
72 666 444 333 232,322,323,223,232 222 122,122,212,212,221,
221,222
1,2,4 cir 1,2,3,6 cir 1,2,4,8 cir 1,2 cir 1,2,3,4,6,12 cir 1,2 cir
84 777 455,545,554 343,434,434,343 233,332,333,323,333 322,232,223 222
1,2,4 cir 1,2 cir 1,2,4 cir 1,2 cir 1,2,4 cir 1,2,7,14 cir
90 787,878,878,787 555 344,434,443,444,444,344, 333 232,323,323,232 322,222,232,222,223,222,
434,443 222
1,2 cir 1,2,3,6 cir 1,2 cir 1,2,5,10 cir 1,2,3,6 cir 1,2 cir
96 888 655,565,556 444 433,334,333,343,333 233,323,332 322,322,232,232,223,223,
222
1,2,4 cir 1,2 cir 1,2,4,8 cir 1,2 cir 1,2,4 cir 1,2 cir
108 999 666 454,545,545,454 434,344,343,443,434 333 323,232,332,323,233,232,
323
1,2,4 cir 1,2,3,6 cir 1,2,4 cir 1,2 cir 1,2,3,4,6,12 cir 1,2 cir
120 10 10 10 677,767,776 555 444 433,343,334 233,333,323,333,332,333,
333
1,2,4 cir 1,2 cir 1,2,4,8 cir 1,2,5,10 cir 1,2,4 cir 1,2 cir

table pContinued
Coil grouping for three-phase windingsskip pole ConneCtion (1-7)Cont.

number of poles
slots 16 18 20 22 24
48 groups of 1
48 111
1,2,4,8,16 cir
6 groups of 2
54 211,111,112,111,111,121,111,111,111,111, 111
121,111,111,211,111,112
1,2 cir 1,2,3,6,9,18 cir
60 211,121,112,111,111,211,121,112 211,111,111,121,111,111,112, 111
111,111
1,2 cir 1,2 cir 1,2,4,5,10,20 cir
72 121,212,212,121 211,121,112 211,112,111,121,111 211,111,111,112,111,111,111, 111
121,111,111,111
1,2,4,8 cir 1,2,3,6 cir 1,2,4 cir 1,2 cir 1,2,3,4,6,8,12,24 cir
84 122,212,221,222,222,122,212,221 221,221,212,212,122, 121,211,212,112,121 211,121,112,112,111,211,121, 211,111,121,111,112,111,111,
1,2,4 cir 122,112,121,211 121,112,111,211 211,111,121,111,112
1,2 cir 1,2,4 cir 1,2 cir 1,2,4 cir
90 122,222,221,222,222,212,222,222,222,222, 122,212,221 121,212,212,121 121,211,121,211,212,111,212, 211,121,112,111,111,211,
212,222,222,122,222,221 112,121,112,121 121,112
1,2 cir 1,2,3,6 cir 1,2,5,10 cir 1,2 cir 1,2,3,6 cir
96 222 122,221,222,212,221, 212,122,121,221,212 121,212,121,211,212,121, 211,121,112
222,122,212,222 212,112,121,212,121
1,2,4,8,16 cir 1,2 cir 1,2,4 cir 1,2 cir 1,2,4,8 cir
108 322,232,223,222,222,322,232,223 222 122,221,222,212,222 212,122,212,122,121,222, 121,212,212,121
1,2,4 cir 121,221,212,221,212
1,2,3,6,9,18 cir 1,2,4 cir 1,2 cir 1,2,3,6,12 cir
120 232,323,323,232 322,223,222,232,223, 222 222,122,212,222,221,222, 122,212,221
222,322,232,222 122,222,212,221,222
1,2,4,8 cir 1,2 cir 1,2,4,5,10,20 cir 1,2 cir 1,2,4,8 cir

Figure A
Frame Shell
Back Iron
Outer Perimeter Of
Stator Lamination
1/2 Tooth Length
Average Tooth Width 1/2 Tooth Length

(measure with micrometer
or vernier caliper)
Bore Diameter
(inside diameter)
Figure B
Gross Core Length
Finger
Plate
Finger Plate Air Duct Width Lamination
Stator Core
Important Five core dimensions are needed to calculate the air-gap, tooth and back-
Information iron densities: 1) bore diameter; 2) core length; 3) number and width of air
For Taking vents; 4) depth of stator back iron; and 5) stator tooth width. Figures A and B
(above) illustrate these dimensions.
Measurements
The bore diameter is the inside diameter of the stator corei.e., the distance
from the top of one tooth to the top of the tooth directly across the stator.
The gross core length is the total length of the stator core lamination, includ-
ing the ventilation or air ducts. (The finger plates at the core ends are not
included in this measurement.) To get the net core length (i.e., the active

iron length for tooth and back-iron areas), subtract the distance across all air
vents in the core from the gross length.
The number and width of air ducts, when used, must also be recorded on
the data sheet.
The depth of back iron is the distance from the bottom of the slots to the
outside of the lamination. It does not include the thickness of the frame
shell. If this distance varies, use the shortest dimension. Always measure
the depth of the back iron in thousandths.
The average tooth width is the width of the iron between adjacent slots. It
should be measured about halfway down its length unless the tooth is very
narrow at one point. Accurate measurement of the tooth width is critical in
many redesigns. Consequently, this measurement should always be made
with a micrometer or a vernier calipernever with a tape or ruler!

Glossary
AWG: American Wire Gauge.
Adjacent pole connection: See short jumper.
Air gap: The distance between the stator and the rotor.
Air-gap area: The total area around the bore.
Ambient temperature: The temperature of the atmosphere surrounding the

equipment.
Chord factor: Ratio of the resultant voltage induced in a coil to the arith-
metic sum of the magnitudes of the voltage induced in the two coil sides.
Chorded winding: A winding with a span less than full pitch. The chord
factor is less than 1.0.
Circuits: Number of paths the current can flow through, from one end of a
phase to the other end.
Circular mil area: Cross-sectional area of wire.
Cogging: A variation in motor torque at very low speeds caused by variations

in the magnetic flux due to alignment of the rotor and stator teeth at various
positions of the rotor.
Coil span: The slots in which the two sides of a coil lie.
Concentric winding: A winding in which each coil in a group of coils has a

different span.
Conductor: A wire or combination of wires that carries the current.
Consequent-pole winding: A winding in which the polarity of all groups is

the same.
Constant horsepower: A multispeed motor in which the rated horsepower is

the same for all speeds.
Constant torque: A multispeed motor for which the rated horsepower varies
in direct ratio to the synchronous speeds.
Core loss: That portion of electrical losses in a unit caused by the magnetiza-
tion of the iron.
Cusp: A decrease in torque as the motor begins to accelerate.

Delta connection: A three-phase winding in which the ends of a given phase
are each connected to the end of another different phase.
Distribution factor: The ratio of the resultant voltage induced in a series-

connected group of coils to the arithmetic sum of the magnitudes of the
voltages induced in the coils.
Efficiency: Ratio of output power divided by input power.
Even grouping: The coil groups in a winding have the same number of coils.
Flux: The lines of magnetism set up in a core.
Form-wound coil: A coil made with rectangular or square wire.
Frequency: Number of cycles in a time period (usually one second).
Full-load current: The current required by a motor to develop its rated

output power.
Full-load torque: Torque a motor must develop to produce its rated output
power.
Group: Coils that make up one pole of one phase.
Horsepower: The output rating for motors manufactured in North America;

equal to 33,000 foot-pounds of work per minute.
IEC: International Electro Technical Commission.
Kilowatt: A unit of electrical power. Output rating of motor manufactured

and used off the North American continent.
Lap winding: A winding in which all coils have the same span.
Locked-rotor current: Current drawn by a motor when its rotor cannot turn.
Locked-rotor torque: Torque produced by a motor when its rotor cannot

turn.
Long jumper: A method of internally connecting coil groups of a phase

in series in which every other group is bypassed. Also referred to as 1-7
jumper, skip pole.
Mush coil: A coil made with round wire.
NEMA: National Electrical Manufacturers Association.

Odd grouping: The coil groups in a winding do not have the same number of
coils.
Open slot: A slot with a wide opening at the bore to accept a form-wound
coil.
Overload: Operating motor at a higher horsepower or KW rating than it was

designed for.
Part-winding start: A motor designed to start with only a portion of its

winding energized.
Pattern: Repeatable manner in which coil groups are inserted in a winding

with odd grouping.
Peripheral speed: The speed at which a point on the outside diameter of a

rotating part is moving.
Phase voltage: Voltage impressed across the phase coils of a winding. In a

three-phase winding, phase voltage equals line voltage for a delta connection,
and 58 percent of line voltage for a star connection.
Power factor: The ratio of watts to volt-amperes in a given phase.
RPM: Revolutions per minute.
Radius factor: The amount subtracted from the cross-sectional area of a

rectangular or square wire due to the rounded corners.
SIN or Sine: A trigonometric function. Find the value in a trigonometry table

or use the SIN key on your calculator.
SWG: Standard Wire Gauge (British).
Salient pole winding: A winding in which the polarity of the groups

alternate.
Secondary voltage: The voltage across the slip rings of a wound-rotor motor.
Section: The number of coil groups in a winding before the pattern repeats.
Service factor: Percent of overload that a motor can carry without

overheating.
Short jumper: An internal connection whereby adjacent poles of a given

phase are connected in series. Also referred to as adjacent pole, 1-4 jumper.
Skip pole: See long jumper.

Slip: Drop in motor speed from synchronous speed to operating speed.
Star connection: A three-phase winding in which one end of each phase

is tied together to make a star point. The other ends are connected to the
power source. Also called wye or Y connection.
Strands: Individual wires making up a conductore.g., 5 #14 means 5

strands of #14 wire
Synchronous speed: Speed of rotation of the magnetic field; equal to:

120xhertz

poles
T-frame: Suffix to frame numbers of rotating equipment built to NEMA
standards after the mid-1960s.
Temperature rise: Increase in temperature of a winding from room

temperature to its level-out temperature.
Torque: The turning force of a motor; usually expressed in pound-feet or

Newton-meters.
U-frame: Suffix to frame number of rotating equipment built to NEMA

standards between the mid-1950s and the mid-1960s.
Variable torque: A multispeed motor in which the horsepower ratios vary as

the square of the speed ratios.
Vintage: Same Era. Compare T frames with T frames, IEC frames with
IEC frames.
Volts per coil: Voltage stress across a coil.
Wye-delta starting: A method of starting a three-phase motor in which the

windings are connected wye for starting, then changed to delta when the
motor is up to speed. Also referred to as star-start, delta-run.

Symbols Used In Formulas
AGD = air-gap density
B = bore diameter
CC = connection changes
CF = chord factor
CM = circular mils
CM/A = circular mils per ampere
E = voltage
F = frequency
GCL = gross core length
hp = horsepower
kW = kilowatts
N = circuits
P = poles
S = slots
T = turns, torque in lb-ft

314-993-2220 Fax: 314-993-1269 www.easa.com
Version 0214 EA-0615

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AC Motor

Electrical Apparatus Service Association, Inc.

Electrical Apparatus Service Association, Inc.

ii Electrical Apparatus Service Association, Inc. 1990-2014

Electrical Apparatus Service Association, Inc. 1990-2014 iii

iv Electrical Apparatus Service Association, Inc. 1990-2014

Since flux density calculations result in five- to eight-digit figures, it is best to

My thanks to EASA Staff Engineer Preben Christensen and the 1989-90

Electrical Apparatus Service Association, Inc. 1990-2014 v

vi Electrical Apparatus Service Association, Inc. 1990-2014

CM1 = circular mil area per turn of the original winding

T1 = turns per coil of the original winding

T2 = turns per coil of the new winding

Sample T1 = 10 turns per coil, 1-#15 (AWG) wire

Electrical Apparatus Service Association, Inc. 1990-2014 1

2 Electrical Apparatus Service Association, Inc. 1990-2014

5x 4160 = 9 turns per coil

The new thickness (T) changes to:

.171 x 5 = .095 Ground wall

[4.34 x 5 = 2.4 mm]

Electrical Apparatus Service Association, Inc. 1990-2014 3

TABLE 1.2 TABLE 1.3

Tables courtesy of Phelps Dodge Magnet Wire Corp.

4 Electrical Apparatus Service Association, Inc. 1990-2014

19968 x 1.2732 = 25,423 circular mils

Use 7-#15 and 1-#16 (AWG).

If any reduction is to be made on an ac winding in changing from aluminum

Electrical Apparatus Service Association, Inc. 1990-2014 5

T2 = new turns per coil

Motors designed for operation on medium- or high-voltage lines also may

6 Electrical Apparatus Service Association, Inc. 1990-2014

Sample Rating: 1.5 hp, 1800 rpm, 230/460 volts.

Redesign for 575 volts.

#20 wire (AWG) = 1020 circular mils

Using the forumla from Page 1:

CM2 = 1020 x 32 = 816 circular mils

Electrical Apparatus Service Association, Inc. 1990-2014 7

8 Electrical Apparatus Service Association, Inc. 1990-2014

T2 = new turns per coil

T1 = original turns per coil

hp1 = original horsepower

kW1 = original kilowatts

hp2 = new horsepower

kW2 = new kilowatts

Be sure to stay with either hp or kW and do not mix theme.g.,

Electrical Apparatus Service Association, Inc. 1990-2014 9

10 Electrical Apparatus Service Association, Inc. 1990-2014

Sample Rating: 50 hp, 1800 rpm, 230/460 volts, 60 hertz.

Redesign for 60 hp.

T2 = 13 x = 11.87 Use 12 turns per coil.

= 1,941,669 magnetic lines of flux for each pole

Phase volts = line volts for delta connection.

Phase volts = line volts x .58 for star connection.

DF = distribution factor. See Table J, Page 117. (In this example

Air-gap area = 3.14 x bore diameter x core length

= 3.14 x 9 x 6.625 = 187 square inches

Electrical Apparatus Service Association, Inc. 1990-2014 11

= 6.625 x .312 x 48 x .95 = 94.3 square inches

Back-iron area = core length x back iron x .95

= 6.625 x 1.25 x .95 = 7.87 square inches

= 65,207 magnetic lines of flux per square inch

= 129,307 magnetic lines of flux per square inch

= 123,359 magnetic lines of flux per square inch