EEE2330

Testing of D.C. Machines

Introduction
There are several tests that are conducted upon a d.c. machine (generator or motor) to judge its
performance. One important test is performed to measure the efficiency of a d.c. machine. The
efficiency of a d.c. machine depends upon its losses. The smaller the losses, the greater is the
efficiency of the machine and vice-versa. The consideration of losses in a d.c. machine is important
for two principal reasons. First, losses determine the efficiency of the machine and appreciably
influence its operating cost. Secondly, losses determine the heating of the machine and hence the
power output that may be obtained without undue deterioration of the insulation. In this chapter,
we shall focus our attention on the various methods for the determination of the efficiency of a d.c.
machine.
Efficiency of a D.C. Machine
The power that a d.c. machine receives is called the input and the power it gives out is called the
output. Therefore, the efficiency of a d.c. machine, like that of any energy-transferring device, is
given by;
Output
Efficiency = (i)
Input
Output = Input - Losses and Input = Output + Losses
Therefore, the efficiency of a d.c. machine can also be expressed in the following forms:
Input−Losses
Efficiency = (ii)
Input
Output
Efficiency = (iii)
Output+Losses
The most obvious method of determining the efficiency of a d.c. machine is to directly load it and
measure the input power and output power. Then we can use Eq. (i) to determine the efficiency of
the machine. This method suffers from three main drawbacks. First, this method requires the
application of load on the machine. Secondly, for machines of large rating, the loads of the required
sizes may not be available. Thirdly, even if it is possible to provide such loads, large power will
be dissipated, making it an expensive method.
The most common method of measuring the efficiency of a d.c. machine is to determine its losses
(instead of measuring the input and output on load). We can then use Eq. (ii) or Eq. (iii) to
determine the efficiency of the machine. This method has the obvious advantage of convenience
and economy.
a) Efficiency By Direct Loading
In this method, the d.c. machine is loaded and output and input are measured to find the efficiency.
Brake test
In this method, a brake is applied to a water-cooled pulley mounted on the motor shaft as shown
in Fig. (1.1). One end of the rope is fixed to the floor via a spring balance S and a known mass is
suspended at the other end.

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Fig 1.1: Rope brake

If the spring balance reading is S kg-Wt and the suspended mass has a weight of W kg-Wt, then,
Net pull on the rope = (W - S) kg-Wt = (W - S) x 9.81 newtons
If r is the radius of the pulley in metres, then the shaft torque Tsh developed by the motor is
𝑇𝑠ℎ = (W − S) x 9.81 x r N − m
If the speed of the pulley is N r.p.m., then,

2πNTsh 2πN x (W − S)x9.81 x r

Output power = = Watts
60 60
Let V = Supply voltage in volts
I = Current taken by the motor in amperes
Therefore,
Input to motor = V I watts
2πN(W − S)x r x9.81
Efficiency =
60 x VI

Disadvantages
i. The output of the motor cannot be measured directly
ii. This method cannot be used for determining internal losses and efficiency of large
machine, since testing of a large machine entails a considerable loss of energy.

b) Swinburne’s Method for Determining Efficiency

In this method, the d.c. machine (generator or motor) is run as a motor at no-load and losses of the
machine are determined. Once the losses of the machine are known, its efficiency at any desired
load can be determined in advance. It may be noted that this method is applicable to those machines
in which flux is practically constant at all loads e.g., shunt and compound machines. Let us see
how the efficiency of a d.c. shunt machine (generator or motor) is determined by this method. The
test insists of two steps:
(i) Determination of hot resistances of windings
The armature resistance and shunt field resistance are measured using a battery, voltmeter and
ammeter. Since these resistances are measured when the machine is cold, they must be converted
to values corresponding to the temperature at which the machine would work on full-load.

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Generally, these values are measured for a temperature rise of 40°C above the room temperature.
Let the hot resistances of armature and shunt field be Ra and Rsh respectively.

Fig 1.2: Swinburne’s test

(ii) Determination of constant losses
The machine is run as a motor on no-load with supply voltage adjusted to the rated voltage i.e.
voltage stamped on the nameplate. The speed of the motor is adjusted to the rated speed with the
help of field regulator R as shown is Fig. (1.2).
Let V = Supply voltage
I0 = No-load current read by ammeter A1
Ish = Shunt-field current read by ammeter A2
Therefore,
No-load armature current, Ia0 = I0 - Ish
No-load input power to motor = VI0
No-load power input to armature = V Ia0 = V(I0 - Ish)
Since the output of the motor is zero, the no-load input power to the armature supplies (a) iron
losses in the core (b) friction loss (c) windage loss (d) armature
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Cu loss [Ia0 R a or (I0 − Ish )2 R a ].
Constant losses, WC = Input to motor - Armature Cu loss
Wc = VI0 − (I0 − Ish )2 R a
Since constant losses are known, the efficiency of the machine at any other load can be determined.
Suppose it is desired to determine the efficiency of the machine at load current I. Then,
Armature current, Ia = I - Ish ... if the machine is motoring
= I + Ish ... if the machine is generating
Efficiency when running as a motor
Input power to motor = VI
Armature Cu loss = Ia2 R a = (I − Ish )2 R a
Constant losses = WC found above
Total losses = (I − Ish )2 R a + 𝑊𝐶

Therefore,
Input−Losses VI− (I−Ish )2 Ra −WC
Motor efficiency, ηm = =
Input VI
Efficiency when running as a generator
Output of generator = VI
Armature Cu loss = (I + Ish )2 R a
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Constant losses = WC found above

Total losses = (I + Ish )2 R a + 𝑊𝐶
Therefore,
Output VI
Generator efficiency, ηg = =
Output+Losses VI +(I+ Ish )2 Ra +𝑊𝐶

Advantages of Swinburne’s test

i. The power required to carry out the test is small because it is a no-load test. Therefore, this
method is quite economical.
ii. The efficiency can be determined at any load because constant losses are known.
iii. This test is very convenient.
Disadvantages of Swinburne's test
i. It does not take into account the stray load losses that occur when the machine is loaded.
ii. This test does not enable us to check the performance of the machine on full-load. For
example, it does not indicate whether commutation on full load is satisfactory and whether
the temperature rise is within the specified limits.
iii. This test does not give quite accurate efficiency of the machine. It is because iron losses
under actual load are greater than those measured. This is mainly due to armature reaction
distorting the field.

c) Regenerative or Hopkinson’s-Test
This method of determining the efficiency cf a d.c. machine saves power and gives more accurate
results. In order to carry out this test, we require two identical d.c. machines and a source of
electrical power.
Principle
Two identical d.c. shunt machines are mechanically coupled and connected in parallel across the
d.c. supply. By adjusting the field excitations of the machines, one is run as a motor and the other
as a generator. The electric power from the generator and electrical power from the d.c. supply are
fed to the motor. The electric power given to the motor is mostly converted into mechanical power,
the rest going to the various motor losses. This mechanical power is given to the generator. The
electrical power of the generator is given to the motor except that which is wasted as generator
losses.
Thus the electrical power taken from the d.c. supply is the sum of motor and generator losses and
this can be measured directly by a voltmeter and an ammeter. Since the power input from the d.c.
supply is equal to the power required to supply the losses of the two machines this test can be
carried out with a small amount of power. By adjusting the field strengths of the machines, any
load can be put on the machines. Therefore, we can measure the total loss of the machines at any
load. Since the machines can be tested under full-load conditions (of course at the expense of
power equal to the losses in the two machines), the temperatures rise and commutation qualities
of the machines can be observed.

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Circuit
Fig. (1.3) shows the essential connections for Hopkinson’s test. Two identical d.c. shunt machines
are mechanically coupled and are connected in parallel across the d.c. supply. By adjusting the
field strengths of the two machines, the machine M is made to run as a motor and machine G as a
generator. The motor M draws current I1 from the generator G and current I2 from the d.c. supply
so that input current to motor M is (I1 + I2). Power taken from the d.c. supply is VI2 and is equal to
the total motor and generator losses. The field current of motor M is I4 and that of generator G is
I3.

Fig 1.3: Hopkinson’s test

Calculations
If V be the supply voltage, then,
Motor input = V (I1 + I2 )
Generator output = VI1
We shall find the efficiencies of the machines considering two cases viz. (i) assuming that both
machines have the same efficiency (ii) assuming iron, friction and windage losses are the same in
both machines.

(i) Assuming that both machines have the same efficiency h

Motor output = 𝛈 x motor input = 𝛈 V (I1 + I2 ) = Generator input
Generator output = 𝛈 x generator input = x 𝛈 V (I1 + I2 )= η2 V (I1 + I2 )
But generator output is VI1 , therefore,
η2 V (I1 + I2 ) = VI1 or
I1
η=√
I1 +I2

This expression gives the value of efficiency sufficiently accurate for a rough test. However, if
accuracy is required, the efficiencies of the two machines should be calculated separately as below.

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(ii) Assuming that iron, friction and windage losses are same in
both machines.
It is not to assume that the two machines have the same efficiency. It is because armature and field
in the two machines are not the same.
However, iron, friction and windage losses in the two machines will be the same because the
machines are identical. On this assumption, we can find the efficiency each machine as under:
Let Ra = armature resistance of each machine
I3 = field current of generator G
I4 = field current of motor M
Armature Cu loss in generator = (I1 + I3 )2 𝑅𝑎
Armature Cu loss in motor = (I1 + I2 − 𝐼4 )2 𝑅𝑎
Shunt Cu loss in generator = VI3
Shunt Cu loss in motor = VI4
Power drawn from the d.c. supply is VI2 and is equal to the total losses of the motor and generator
VI2 = Total losses of motor and generator
If we subtract armature and shunt Cu losses of the two machines from VI2, we get iron, friction
windage losses of the two machines.
Iron, friction and windage losses of two machines (M and G)
W = VI2 − [(I1 + I3 )2 𝑅𝑎 + (I1 + I2 − 𝐼4 )2 𝑅𝑎 + VI3 + VI4 ]
Iron, friction and windage losses of each machine = W/2

For generator
Output of generator = VI1
W
Total losses = + (I1 + I3 )2 R a + VI3 = Wg
2
VI1
Generator efficiency, ηg =
VI1 +Wg
For motor
Input to motor = V(I1 + I2 )
W
Total losses = (I1 + I2 − I4 )2 R a + VI4 + = Wm
2
Input−Losses V(I1 +I2 )−Wm
Motor efficiency, ηm = =
Input V(I1 +I2 )

Advantages of Hopkinson’s Test

The advantages of Hopkinson’s test are:
i. The total power required to test the two machines is small compared with the full-load
power of each machine.
ii. The machines can be tested under full-load conditions so that commutation qualities and
temperature rise can be checked.
iii. It is more accurate to measure the loss directly than to measure it as the difference of the
measured input and output.
iv. All the measurements are electrical which are simpler and more accurate than mechanical
measurements.
Disadvatage
 Two identical machines are not easily available
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