Pole phase group (PPG) hookup

Move PPG leads by bending them into the bore. Trim phase papers as previously described.

The PPG starts will be the leads coming from the bottom of the stator slot (the outside leads) and the finishes will be the leads coming out of the top of the slots (the inside leads).

Pull the PPG finishes out straight. Pull the starts out and bend them back so that they are laying on the outside of the stator frame.

Using the diagram of the winding made when data were taken, determine two leads that will connect together. For example, the finish of group 1 connects to the finish of group 4 in a four-pole series connection.

Estimate the sleeving needed on each lead to insulate the lead to the point of connection. Make connections on the crown of the winding or on the outside of the winding; this will prevent the buildup of connections in the bore that might contact the rotor. If it is available, use a different color of sleeving for each phase.

The sleeving should be as small in diameter as possible and still slip over the phase group leads.

Cut the sleeving to the estimated length. Slip the sleeving over the PPG leads.

Remove 1 inch of insulating film from the end of each magnet wire in the PPG leads with a wire stripper.

Select the start of the number 1 group. Make all connections relative to this group. This can be any group and will be the start of A phase.

All tape or markers used to mark the start must be removed from the finished winding.

Mark the start using marking tape, numbered markers, or a twist in lead. Numbered tags may be used on all the leads.

Find the finish of the number 1 group by tracing it out, using a continuity tester or a multimeter. Consult the diagram drawn when the motor data was taken and determine where the finish of #1 group connects. For example, in a short jumper four-pole winding, it connects to the finish of the number 4 group.

Count from the number 1 group finish to the number 4 group finish. Count either clockwise or counterclockwise, but be consistent. Twist the finishes together loosely below the cleaned wire.

From the connection diagram, determine where the start of the number 4 group hooks up. For example, in a four-pole short jumper connection, the number 4 group start hooks to the number 7 group start.

Begin at the start of the number 1 group and count to the number 4 group start in the same direction as hookup began.

Hold the number 4 group start in one hand. Continue counting to the number 7 group start.

Twist the number 4 group start and the number 7 group start together loosely below the cleaned wire. Consult the diagram to determine where the number 7 group finish connects. The number 7 finish connects to the number 10 finish in a four-pole series connected wye.

Locate the number 7 finish by counting from the number 1 finish. Hold the number 7 finish and continue counting to the number 10 finish.

Twist these finishes together loosely below the cleaned wire. The number 10 group start becomes the finish of A phase. Label this lead with tape or a number marker.

The first group in B phase will be group 5 since the 1–3–5 skip group method is being used here.

Consult the diagram and determine the first group in B phase.

Locate the start of the number 5 group by counting from the number 1 group start in the same direction previously used. Mark this lead in the same manner as the A phase lead was marked.

Consult the diagram. Connect and label B phase groups in the same manner as A phase groups.

Consult the diagram and connect C phase in the manner described for A and B.

Starts should be separated 120 mechanical degrees. Finishes should be interspaced 120 degrees apart between the starts.

Connect the winding wye.

Phase finishes will be the starts of PPG 10, 2, and 12.

Connect the finishes of all three phases.

Bring the starts of groups 1, 5, and 3 out for line leads (T1, T2, and T3).

Testing the winding

Enter results of all tests in the appropriate section of the motor data sheet (electrical).

Prepare the winding for test by twisting together the cleaned wire of each pair that has already been joined together. Twist together the cleaned wire of leads going to the star.

Twist together the clean wire of the line leads. Take a ground reading using a megohmmeter 1863 or 1644. The reading must be above 100 megohms for a rewound motor. If the ground reading is good, disconnect the test equipment and separate the line leads only.

Ensure all twisted connections are tight. A high resistande connection can give a false or erratic reding,

Use a Kelvin bridge or equivalent instrument to conduct a phase balance test. Test phase balance between starts 1 and 5, 5 and 3, 3 and 1. Calculate readings.

If the readings are satisfactory, proceed to surge test the winding. Surge test between starts 1, 5, 3, and ground. Determine the condition of the winding.

To change the wye connection to a delta

Ensure all leads are properly marked prior to any disconnecting, then disconnect the phase finishes.

Connect:
• A phase finish to B phase start (start 10 to start 5)
• B phase finish to C phase start (start 2 to start 3)
• C phase finish to A phase start (start 12 to start 1)

Conduct the following tests:
• Insulation resistance-to-ground test (megohmmeter 1863 or 1644)
• Phase balance test
• Surge comparison test

When all tests are satisfactory and the connection is in accordance with the data, the connection is ready to be made permanent.