Preparation for coil insertion

Carefully lay out previously prepared insulating materials, phase windings, and required tools.

Place stator in a stator holder and secure.

Insert the protective paper liner.

Insert slot cell insulation in the slot where the first coil side will be installed (slot 1). Spread the two sides of the insulation to make coil insertion easier.

Position the coil rack so that the A phase coils are in line with the stator.

Coil insertion

Take the first coil from the first group of A phase and remove the twine from the coil side that is to be installed in the first slot.

Flatten the coil between the thumb and index finger of each hand and feed the coil into the slot.

Press the ends of the coil down so they clear the stator bore.

Insert a coil separator over the installed coil side.

The installation of one slot cell insulator at a time will greatly reduce the chances of skipping a slot. Also, there is less chance of injuring your fingers or hands by cutting them on additional installed slot cell insulation.

Continue to install one slot cell insulator, one coil side, and one coil separator until one span is completed. Ensure the crossovers are placed in the slot first to produce a neater looking job.

When the first group of A phase has been installed, prepare and install the first group of B phase.

Tamp the flat coil separator tightly with a tamping wedge before putting a second coil side in a slot.

After one span has been laid in, install the next group by putting one coil side in an empty slot and the other coil side into a slot that contains a coil and a coil side separator.

Insert a temporary fiber slot stick (wedge) to hold wires in place on top coil side.

When the first group of B phase has been installed, prepare and install the first group of C phase.

Installing remaining coils in the stator

Continue installation, beginning with second group of A phase, second group of B phase, then second group of C phase.

Continue this sequence of rotation until all coils have been installed in the stator. Use slot cell insulation coil side separators, slot sticks, slot wedges, and phase insulation material.

After all coils have been installed, there should only be six leads extending from the stator.

Inspect the entire winding to ensure that all slots are properly closed.

Ensure that the coil end turns are free of nicks and scrapes.

Making connections

To make a wye connection:
• Start from either the right or left.
• Take every other lead and tie them together to make the wye connection.

The remaining three leads will be the line leads.

To make a delta connection, connect pairs of adjacent leads together. This gives the delta connection and the line leads.