Winding phase group hookup

Remember a phase group lead may have more than one wire, depending on the "in hand" number the winding specifications require.

Cut one of the pole phase group (PPG) connections just below the temporary connection. Remove all tape and markers.

The connections must be made on the crown of the winding or outside of the crown to prevent the connections from rubbing on the rotor.

Lay the PPG leads along the crown of winding to determine the length of lead needed for the connection. Determine the point at which the leads from the PPGs will cross the windings when dressed (insulated).

Measure about 1½ inches more lead than the length to the point of crossing for each phase group lead. Cut off the rest of the lead.

Do NOT remove any copper when stripping the insulation film.

Use the wire strippers to remove about 1 to 1½ inches of insulating film from the magnet wire. Select a sleeving large enough to slip snugly over the phase group lead sleeving, and long enough to reach the core slot.

When measuring the large sleeving for cutting, ensure that the phase group lead sleeves are pushed completely into the slots.

Cut a piece of the larger sleeving long enough to cover the soldered connection and overlap the two phase group lead sleeves by at least 1 inch on each side. This piece should fit snugly over the phase lead sleeving.

Slip the large sleeving over one of the phase group lead sleeves before twisting them together for soldering.

Using a Western Union-style splice will provide the strongest connection and facilitate sliding the insulation over the splice.

Make the connection by twisting stripped wire, then trim the excess wire from the connection.

Repeat the same process on all the other temporary connections except star and line leads. Solder all connections.

Wye connection

Care must be taken to ensure that enough wire is available when the temporary connection was made.

Bring the three leads around the crown and measure where they will meet with enough wire to connect them together. Slide a piece of the small insulation over each wire just as before. Strip a 1½ inch area from the end of each wire.

The Star connection will be made with the same Western Union splice as before, using two wires on one side and one wire on the other.

Slide a piece of the larger insulation over the two wire side to be sure it fits before twisting the wires together. Solder the connection. When the connection has cooled, slide the insulation into place over the connection.

Line connections

The size of the lead wire is a function of the horsepower of the motor.

Break the insulation braid 2 inches above the connection sleeving. Do NOT cut the insulation. Varnish will seal the braid to prevent wicking.

Remember that a phase group lead may have more than one wire, depending on the "in hand" number the winding specifications require. The lead wire in a Wye connected motor will have one phase group lead; the lead wire in a delta connection will have at least two phase group leads connected. This connection will require care in selecting a sleeving. The lead wire should be long enough to be laced at least halfway around the winding before going to the motor junction box.

Dress and measure three stranded lead wires. Slip a piece of insulation over the lead wire large enough to cover the connection and T-lead insulation. Splice the stranded wire to the magnet wire

Broken braid on the lead wire should be outside the sleeving to permit a varnish seal.

The motor connections can now be soldered.

When all connections are soldered and cool, slip the large sleeves in each connection over the connections.

Tie down the end of the winding.