Motor Winding Procedure

Hello everyone, i am Niko and, in this instructables i will show
you, how to rewind and renew old three phase electric motor.
If you are searching for rewinding of one phase motor you

can find it here.
In this insctructables, i am going to make step forward. In next

steps I will show you how to analyse motors winding,
disassemble motor, remove bearings, calculate new winding,
rewind motor, reassemble it with new bearings and test motor.
Rewinding is very long process. It took about two days to
rewind it, replace all old parts and reassemble it.
If you have any questions you can easily message me
Step 1: Analyse Motor

Three phase asynchronous motor is most common used
motor in the world. It has very good efficiency and low
manufacture and maintain costs. Two main parts of motor are
rotor and stator. Rotor is usually made as squirrel-cage, and it
is inserted in stators hole. Stator is made out of iron core and
winding.
Stator is used to generate magnetic field. 3 phases generates

rotation magnetic field so we don't need capacitor on three
phase motor. Rotation magnetic field "cut" squirrel-cage,
where it induces voltage. Because cage is short-circuited,
voltage generates flow of electric current. Current in magnetic
field generates force.
Step 2: Analyse Motor
Because magnetic field must rotate faster than rotor to induce

voltage in rotor. That's why motor speed is a little bit less then
magnetic field speed ((3000 rpm [Magnetic field] -- 2810 rpm
[Electric motor])). That's why we call them Three
phase ASYNCHRONOUS electric motor.
Motors Inscription board
On the motors inscription board we can find most useful

information about motor:
 Motors nominal voltage (for star (Y) and triangle (D) motor

connection) [V]
 Motors nominal current (for star (Y) and triangle (D) motor
connection) [A]
 Power of the electric motor [W]
 Power factor cosFi
 Rotation speed [rpm]
 Nominal frequency [Hz]
Step 3: Analyze Winding

Open the cover of conduit box.
Before measuring remove all connections in conduction box.
Measure resistance for each winding, resistance between two
different winding and resistance between winding and motors
frame.
Resistances of three winding should be same (+/- 5%).

Resistance between two winding and winding - frame should
be more than 1,5 Mohm.
You can detect burned motors winding by unique smell

(smells like burned lacquer).
Take few picture of motor. Mark spots between first cover and
stator and second cower and stator (we will need this marked
points at motors assemble).
Remove covers from motor. Usually they are attached on

stator by long screws. If you cant separate cover and stator
you can use rubber hammer. Gently hit cover and try to rotate
it. If that wont works, heat it.
Step 5: Disassembling Motor

Remove rotor from stator. You can gently hit rotors axis with
rubber hammer.
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Step 6: Disassembling Motor
Remove ventilator from rotors axis. I had metal ventilator so i
heated it up. I separated it very easily from axis.
Remove clamp, and safety ring if you have one. Then remove
second cover.
Step 7: Removal of Bearings
Use puller to remove bearings on both sides. You must be
careful because you can easily damage the axis of rotor.

Step 8: Removal of Old Winding
First you need to cut old winding from stator. For this job use
hammer and chisels. Try not to damage stators lamellas.
Do same on both sides of stator.

Remove connections and conduit box from stator. In next step
you will need to heat up old coils, and conduit box must be
empty.

Heat up winding with flame torch to burn out the rest of
lacquer.
If you burned old lacquer you should be able to push remain

winding out of stators gaps.

Step 11: Sandblasting
Sandblasting is process where sand hits surface of workpiece
with very high speed and slightly damage it.
You can easily remove old colour form motor with
sandblasting. While sandblasting you need to be careful, that
you don't damage surface too much, especially edges of
cowers.

Step 12: Paint Motor
The colour must withstand at least 100 degrees Celsius.

Make sure you don't paint inscription board.

Step 13: Identification of Old Winding
You can find all information about type of old winding in

"winding head". Winding head is part of winding where all
connections are made.
By the winding head (Type of winding), number of wires in

each gap and thickness of the wire you can rewind new
motors winding without doing calculations in next step.

Step 14: Calculation of Parameters for New Winding
New winding of motor depends of stators package

(dimensions of iron core). For better presentation i made 3D
model of my stators package.
You need to measure following things:
 Length of stators package: lp= 87mm;

 External diameter of statros package: Dv= 128mm;
 Inner diameter of stators package: D= 75.5mm;
 Number of stators gaps: Z= 24;
Now measure dimensions of stators slot.
 Width of stators slot: b1= 6.621mm; b2= 8,5mm;

 Height of stators slot: hu= 13.267mm;
 Opening of stators slot: b0= 2mm;
 Height of slots "neck": a1= 0.641mm;
 Tooth width: bz= 3.981mm;
If you have other shape of slot you look at upper picture.
I copied this picture from book [Neven Srb; Elektromotori].

Step 17: Calculate Number of Pole Pairs
Number of pole pairs depends on nominal frequencies and

rotation speed of magnetic field. You can get rotation speed of
magnetic field by rounding motors speed (2810) to closest
value (3000, 1500, 1000, 750...).

Step 18: Calculate Number of Pole Pairs
I calculated that my motor has 2 pole pairs and it generates
magnetic field as you can see on upper picture.

Step 19: Calculate Pole Stepp
Pole step is distance on inner circle of stator, and it marks

size of each pole.

Step 20: Calculate Pole Surface
Pole surface is marked red on picture two. One pole surface

is exactly half surface of stator, that is because i have 2 pole
motor.

Step 21: Calculate Pole Surface
Because iron core of stator is not made out of pure iron we

need to calculate real package length. You get iron filling
factor from upper table. It depends on type of isolation.

Step 22: Calculation of the Tooth Lenght
Step 23: Calculation of the Height of the Yoke of the
Stator
Stators yoke is part of stators package which extends from

stators tooth to end of package.

Step 24: Calculation of the Yoke Cross Section

Step 25: Calculation of the Cross Section of Teeth of
One Pole

Step 26: Calculation of the Slot Surface

Step 27: Choosing the Type of Winding
I chose type of winding based on my motors specifications. In

winding books there is a lot of different types of winding
diagrams. Each one is drown for different amount of pole
pairs.
I took winding on the picture from winding book. My new

winding was three phase single layer concentric winding.

Step 28: Calculation Number of Slots Per Pole and
Phase

Step 29: Calculation of Pole Step (in Slots)

Step 30: Winding Factor
There is a table in upper picture. You cant pick up winding

factor from table if you have one layer winding.

Step 31: Induction in the Air Gap
Select appropriate value of induction in air gap from table. It

depends on number of pole pairs. If motor is older chose
column I, else chose value from column II.

Step 32: Calculation of the Induction in the Teeth of
the Stator

Step 33: Calculation of the Induction in the Stator
Yoke

Step 34: Calculation of the Magnetic Flux of One Pair
of Poles

Step 35: Calculation of the Calculation Number of
Turns in the Phase

Step 36: Calculation of Calculation Number of Turns
in Slot

Step 37: Determine the Filling Factor
To get right filing factor you need to have surface of your slot.
Then you easily write down filling factor from upper graph.
Filling factor must be between upper and bottom
recommended line.

Step 38: Calculation of Cross Section of the Wire

Step 39: Calculation of Thickness of Wire
According to the result you pick a wire which is in +/-2% range

of result. I picked 0,8mm wire.

Step 40: Winding Diagram
I remade winding diagram from book, so it fits into my stator. I

draw new winding diagram which i had used at winding motor.
Second picture is showing the magnetic field generated by

stators winding. O and X are showing direction of electric
current. Current which is flows inside picture has clockwise
direction of magnetic field. If would had 4 pole motor we
would have 4 areas instead of 2 areas of magnetic field.

Step 41: Isolating Stators Slots
Measure length of slot, and add about 16mm (depends of how
you will twist paper). Cut it and twist it as I have done on gifs.
Put isolate paper on table, and place ruler on it, so you get
about 4mm gap in witch you will insert isolate paper and then
twist it. Use screwdriver to bend it and insert it in gap. It
should fit perfectly so you cant pull it out.

Step 42: Measure Length of Coils
Make model of coil. Place model in right slots, leaving some

free space. You must not leave too much space, because
winding would be too bit, and you must not make it too small,
because you will not be able access to all slots.

Step 43: Winding Coils
Place model in special tool. Free 3d model of winding tools
are available on "Rewinding one phase motor" instructables.
Make sure you wind correct number of turns. After you wind
coil you need to tie it up with piece of wire. Then you can take
it of winding tool.

Step 44: Inserting Coils in Stators Slots
Careful place coils in stators slots. This can take a long time
to do. Be gently so you don't damage wires lacquer. Rotate
coils so their end wires will come out on the side, where is the
hole from stator to electrical clips. You can use wooden stick
to put winding in slots.
Mark ends of coils!

Step 45: Connecting Coils
Wire coils together according to winding diagram. Solder and

isolate them. End of each coil wire to conduit box and extra
isolate them.

Step 46: Bind the Coils
Bind the coils with the stator lacing thread. Sew stator lancing
thread around coils, as you can see on pictures. Tight winding
well.

Step 47: Varnishing the Motor
1. Heat up cooking oven to 100 °C. Put motor in it.
2. When motor heats up, spills lacquer on motors coils as you

see on pictures
3. Turn motor around and do the same
4. You can reuse old lacquer.
5. Put motor in hot oven, and cook it for about 4 hours
6. Take motor out and clean edge (so cover will fit perfectly).
DON'T DO IT INSIDE BUILDING OR KITCHEN!

Step 48: Reassemble Motor
Attach new bearings. Lubricate axis of rotor. You find type of
bearing on side of bearing. If you cant find it, you can
measure it and find number in catalogue on internet.

Attach cover on stator. Watch marks to put it into right place.

Put rotor in stator, and close it with second cover. Screw
motor together.

Connect end of coils to clips, according to picture from

analyse motor.

Put ventilator and last cover on motor. If you have iron
ventilator heat it.

Step 53: Measurement
3 More Images
I took refurbished motor to university to make measurements.

We mounted motor on special test device, and connected it
with measurement equipment. We tested next things:
 Resistance of winding
 Free running test of an electric motor
 Test of the loaded electric motor
 Optimal voltage test
 Short circuit test
 Torque characteristic
*PF = Power factor

Step 54: Conclusion
It took me about a week to rewind this motor. Most time i

spent on calculation of new winding. I had a lot of problems
with calculation but i solved them and i got same parameters
of winding as were on old one.
I had a lot of problems with winding new winding too. First i
made coils too small, and i couldn't insert last coils in slots. I
couldn't access to them because other winding were too
small. Then i decide to make bigger one but i found problem
again. This time winding was too big and i couldn't close the
cover of motor.
Third time i successful rewind motor. Because gap between

stator and cover was very small, i decided to do a little bit
bigger first coils, and a little bit smaller last coils. You can se
that on measurment of resistance where, winding resistances
aren't identical. But in next measurement we can see that
resistances do not dramatically affect on electric motors
performance.
I made all tests with two different voltages. Motor was made
for voltage 380V, but now we have 400V in EU.
In upper table there is data from manufacturer in first line. In

second line is measurement at 380V and third line at 400V. If
we compare all data we can see that motor isn't bad at all. All
parameters are very close together.
I took all electrical equations and orientation tables from

book: Neven Srb ELEKTROMOTORI
I hope you enjoined my presentation of rewinding a three

phase motor. If you have any questions please ask, and i will
try to answer ass soon as possible. Thank you for your
attention.
Best regards Niko

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95 Comments
workinehalemayehu28
27 days ago on Step 54
ReplyUpvote
This is brilliant site for me thanks a lot 🙏
RFT8
Question 4 months ago on Introduction
AnswerUpvote
Hi Niko, these rewinding instructions are very usefull. However, we (my
brother and I) are trying to work out the way to redesign a sinle phase
2200watt/240Volt/50Hz/1500revs motor to a 3 phase
2200watt/400volt/50Hz/1500revs motor. The problems we encounter are that
not only the original tension changes but also the number of phases. The first
result gives us a three phase motor but with a much higher current and
probably also a higher power as the original one...... Rihgt now we're not so
sure anymore if this project is even possible... What is youre opinion about it?
Or what should be the correct way to calculate things?
Kind regards
RFT8
lamprosargyros
4 months ago
ReplyUpvote
Hello Nicko,i am searching for the book but i cant find it,can you suggest me
any other similar book?
1032201141
Question 6 months ago
AnswerUpvote
What was the weight of total winding wire?
bandayhazhar288
Question 9 months ago on Step 27
AnswerUpvote
Step 28 what’s the name book please.
m.reza1996azizi
Question 3 years ago on Step 35
AnswerUpvote
Hello.what is 0.22?
3 answers
tissarathnasooreya
2 years ago
ReplyUpvote
I want 24 slot 2Pol 3 phase 1 kilowatt motor winding diagram, and 48 slot ,3
phase motor diagram and motor winding model, connection diagram please
give me. slot 48 horsepower 55 Motor.
tissarathnasooreya
2 years ago
ReplyUpvote
this is very good Niko thanks for the
information. but how can I find or buy that Neven Srb
ELEKTROMOTORI book
in English?
mdg jayakody
2 years ago
ReplyUpvote
excellent work....
joe99young
Question 3 years ago
AnswerUpvote
Hi in step 18 you calculate the number of poles with the formula p = (60 x f)/
ns, you get 1 as the answer yet you state that you had two pole pairs?
1 answer
hareramm979
Question 2 years ago on Introduction
AnswerUpvote
Is this available in Hindi language
mdabubakararshad786
2 years ago
ReplyUpvote
Tanks alot sir giving briefly explanation 🤗👌
yongkong966
3 years ago
ReplyUpvote
Hello sir, can you make diagram about 54 slots? It has 6 pole.
1 reply
RobB162
5 years ago
ReplyUpvote
Working as an industrial electrician this is counter productive vs purchasing a
new one. However, some fantastic learning to be gained from this. I plan on
having our apprentice look through this and also work through the
calculations. Fantastic detail. Thanks for the time commitment and also for a
great intructable!
1 reply
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Hello everyone, i am Niko and, in this instructables i will show

If you are searching for rewinding of one phase motor you

In this insctructables, i am going to make step forward. In next

If you have any questions you can easily message me

Step 1: Analyse Motor

Stator is used to generate magnetic field. 3 phases generates

Because magnetic field must rotate faster than rotor to induce

Motors Inscription board

On the motors inscription board we can find most useful

 Motors nominal voltage (for star (Y) and triangle (D) motor

Step 3: Analyze Winding

Resistances of three winding should be same (+/- 5%).

You can detect burned motors winding by unique smell

Remove covers from motor. Usually they are attached on

Step 5: Disassembling Motor

Add TipAsk QuestionCommentDownload

Add TipAsk QuestionCommentDownload

Do same on both sides of stator.

Add TipAsk QuestionCommentDownload

Add TipAsk QuestionCommentDownload

If you burned old lacquer you should be able to push remain

Add TipAsk QuestionCommentDownload

Add TipAsk QuestionCommentDownload

The colour must withstand at least 100 degrees Celsius.

Add TipAsk QuestionCommentDownload

You can find all information about type of old winding in

By the winding head (Type of winding), number of wires in

Add TipAsk QuestionCommentDownload

New winding of motor depends of stators package

 Length of stators package: lp= 87mm;

Now measure dimensions of stators slot.

 Width of stators slot: b1= 6.621mm; b2= 8,5mm;

I copied this picture from book [Neven Srb; Elektromotori].

Add TipAsk QuestionCommentDownload

Number of pole pairs depends on nominal frequencies and

Add TipAsk QuestionCommentDownload

Add TipAsk QuestionCommentDownload

Pole step is distance on inner circle of stator, and it marks

Add TipAsk QuestionCommentDownload

Pole surface is marked red on picture two. One pole surface

Add TipAsk QuestionCommentDownload

Because iron core of stator is not made out of pure iron we

Add TipAsk QuestionCommentDownload

Stators yoke is part of stators package which extends from

Add TipAsk QuestionCommentDownload

Add TipAsk QuestionCommentDownload

Add TipAsk QuestionCommentDownload

Add TipAsk QuestionCommentDownload

I chose type of winding based on my motors specifications. In

I took winding on the picture from winding book. My new

Add TipAsk QuestionCommentDownload

Add TipAsk QuestionCommentDownload

Add TipAsk QuestionCommentDownload

There is a table in upper picture. You cant pick up winding

Add TipAsk QuestionCommentDownload

Select appropriate value of induction in air gap from table. It

Add TipAsk QuestionCommentDownload

Add TipAsk QuestionCommentDownload

Add TipAsk QuestionCommentDownload

Add TipAsk QuestionCommentDownload