Motor Rewinding

31/05/2026

Night work

24/05/2026

RPM check

*Hashtags:*

22/05/2026

Submersible Motor Winding – 3 Wire Type
Check the connections before installation.
Save this for later ⚡

21/05/2026

1. Power Supply

230V AC comes in through Live (Red) and Neutral (Black). Earth (Green/Yellow) goes straight to the motor body for safety.

2. ON/OFF Switch

This is the main switch. When ON, it completes the circuit and sends power to the motor. When OFF, it cuts power completely.

3. Capacitor Role

Single-phase motors can’t start on their own. The capacitor creates a phase shift between the main winding and start winding.
- It gives the motor extra starting torque.
- In most small pumps, the capacitor stays connected. In some, a centrifugal switch disconnects it once the motor reaches speed.

4. Overload Protector

This sits in series with the Live wire. If the motor draws too much current or overheats, it cuts the circuit automatically. It prevents the motor from burning out.

5. Motor Windings

Main/Run Winding

Connected directly to power. Keeps the motor running.
- *Start Winding*: Connected through the capacitor. Gives the initial push to start rotation.

Working Flow
Power → Switch → Overload Protector → Motor
Capacitor → Start Winding → Creates phase shift → Motor starts rotating → Pump impeller spins → Water gets pumped

Important
Never run the pump dry. It needs water inside to cool and lubricate the mechanical seal. Running dry will burn the seal in seconds.

*Electrical / DIY Hashtags:*

20/05/2026

Appreciation Vibe
"Behind every machine that runs smoothly, there’s a motor that’s been through hell and back.
Respect the grind.
"

19/05/2026

*Option 1 - Professional:*
*Understanding 3 Phase Motor Windings*
Here’s a look inside a 3 Phase Induction Motor stator and its winding connection diagram.
U1, U2, V1, V2, W1, W2 terminals can be connected in Star or Delta based on voltage requirements.
Perfect for students and technicians learning motor rewinding! ⚡

*Option 2 - Educational / Short:*
*Motor Winding Explained*
Top: Actual stator coils of a 3 Phase motor
Bottom: Connection diagram for Star/Delta wiring
Save this for your next rewinding job! 🔧

*Option 3 - Catchy:*
*Ever wondered what’s inside a 3 Phase Motor?*
This is the heart of it – the stator windings.
Master the connections, master the motor.

19/05/2026

17/05/2026

1. Strip & Inspect

1. Remove end shields and rotor.
2. Cut and pull out the old winding carefully.
3. Count turns per coil and measure wire gauge with a micrometer. Write it down - this is your reference.
4. Check stator for burnt spots, burrs, or damaged slots. Clean everything.

2. Slot Insulation

1. Cut slot liners from 0.25mm pressphan or nomex paper.
2. Insert liners into all slots. Leave 5mm overlap on both ends.
3. Make sure no metal is exposed. This prevents body shorts.

3. Wind the Coils

Use a winding jig or manual winding on a former. Keep turns tight and even.

*For a typical 1.5HP, 24-slot, 2800 RPM motor:*
- *Main winding*: 24 SWG, 45-50 turns/coil, pitch 1-6, 4 coils
- *Auxiliary winding*: 28 SWG, 75-85 turns/coil, pitch 1-8, 4 coils

Wind all coils for one phase first, then the other. Direction matters - keep it consistent.

4. Insert Coils into Slots

1. Start with the bottom layer coils, then top layer.
2. Use a wooden wedging tool to avoid damaging enamel.
3. Tie coils together with cotton lacing thread. Don’t use nylon - it melts during baking.

5. Connections & Testing

1. Connect main winding in series. Connect auxiliary in series with the capacitor.
2. Check for continuity and no shorts between windings and body using a multimeter/megger.
3. Insulation resistance should be >1 MΩ before varnishing.

6. Varnish & Bake

1. Dip or spray with electrical varnish.
2. Bake at 110-120°C for 2-4 hours. This locks coils and improves heat resistance.
3. Test again after baking.

7. Reassemble

Install bearings, rotor, end shields. Check shaft spins freely. Run no-load test for 15 min and check current.

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*Common mistakes to avoid:*
- Wrong turns count → motor overheats or has low torque
- Missing slot liner → instant short
- Skipping bake → winding loosens and burns out
- Wrong capacitor value → motor won’t start or hums

05/05/2024

repair