Gene Vogel
EASA Pump & Vibration Specialist
New features in the EASA AC Motor Verification and Redesign – Version 4 (ACRewind) program enhance the ability for members to submit data electronically for inclusion in EASA’s Motor Rewind Data – Version 4 (MotorDB) program. Jump to the section below on “enhancements” if you’re already familiar with these programs and how they work.
The Version 4 software is a powerful set of tools for members to check the validity of winding data and to redesign windings from concentric-to-lap and for changes in motor performance. A key feature of this latest version of the program is the integration of the MotorDB with the ACRewind program. The availability of both program functions within a common user interface provides more than just convenience. The ability of the programs to share data resources creates new capabilities that the stand-alone version of the program could not.
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The programs
The EASA MotorDB is a member benefit provided to all Active EASA members free of charge. The database contains single-phase, three-phase, AC multi-speed and DC windings with more than 300,000 individual winding entries. The data is a compilation of more than 40 years of submissions from EASA members. Often, a motor is received for repair with winding data that is suspect or not available at all. The MotorDB program provides members with a resource to complete winding repairs confidently. Members of EASA’s technical support staff use the MotorDB regularly to support member requests for original and redesign data. But every EASA member has a copy of the MotorDB for their use in their service center; contact EASA Customer Service (easainfo@easa.com) if you need to purchase an extra copy of the program. A flexible search utility allows users to retrieve winding data matching certain criteria with each of four data stores: Single-phase, three-phase, AC multi-speed and DC.
The EASA ACRewind program is an optional program that members can purchase. When the program is installed, it includes both the rewind data and verification and redesign functions within a single user interface. The ACRewind program allows users to enter original three-phase winding data in concentric or lap format, and either verify flux and current densities for that winding, or choose from a grid of equivalent lap format windings, with the resulting densities and operating parameters.
Enhancements
With Version 4, EASA implemented the ability for members to electronically submit their AC three-phase motor redesign data for inclusion in the MotorDB program. Previously, EASA members built the winding database by submitting paper winding cards that EASA staff manually entered into the database. Hundreds of thousands of records have been entered in that manner. Now members can continue that effort by having the ACRewind program submit the winding data through an internet connection. Once received by EASA, the original data is reviewed by an EASA technical support specialist, screened through a series of technical criteria and then added to the database of AC three-phase windings in the MotorDB program.
To appreciate how this process works, it’s important to understand the way the verification and redesign program is designed to operate when working on a motor. The original winding data is entered into the program's data entry screen, including basic electrical data, winding and connection data and the physical core dimensions. To verify that data, an additional separate screen is displayed with the flux and current densities.
To redesign the winding, a grid of possible redesign options is displayed. The options in the grid are limited to those that match, within tolerance, the desired design criteria. The user selects one or several of the options; for each selected option an additional separate screen is created to display the resulting redesign data. See Figure 1. The user then compares the displayed options and chooses the one that best meets the customer’s needs. To aid in this selection, a convenient side-by-side display is available. See Figure 2. Ideally, when the selection is made, the unselected redesign options are deleted so that only the actual design that’s used is saved in the program for future reference. The saved data will have the original data and the selected redesigned data.
On a periodic basis that saved data is transmitted to EASA via an internet connection where it is processed for inclusion in the MotorDB database. If an internet connection is not available, the data will be written to a separate data file which can be emailed to EASA.
One recent enhancement to the ACRewind program is the addition of a “Send to EASA” checkoff at the top of the original data screen. See Figure 3. This makes it easy for the user to set whether or not a record is sent for inclusion in the MotorDB.
This is an important concern because some members use the program in a manner we had not anticipated. Some users use the program somewhat like a calculator, entering multiple versions of “original” data and verifying each of them to decide which data to use. This leaves a number of slightly different records saved in the program for a single motor.
Unfortunately, if all of these records are sent to EASA, we have no way of knowing which is the authentic original data. But by using the Send to EASA checkoff, the user can indicate which record should or should not be sent. Actually, it would be easier for the user to select redesign options from the grid and avoid having to re-enter original data, but the Send to EASA checkoff will accommodate either approach. Be sure to use the Send to EASA checkoff to insure the correct data is sent.
The program can be set to send the stored data to EASA at intervals of 30 days, or whenever 30 new records have been entered. On the Tools menu, select preferences. On the ACRedesign tab, the last block at the bottom has radio buttons to select Automatic, Prompted or Manual.
When set to manual, data will only be sent when a user selects Send to EASA from the Tools menu. Once data is sent to EASA, it is processed, filtered through a set of criteria and finally entered into the MotorDB database for access by members. The electronic submission from ACRewind is much more efficient than submitting paper winding cards.
Another helpful enhancement to the Version 4 ACRewind program is a “fraction” converter for core dimension data. Data can be entered as “5 5/16” and it will be converted to the decimal equivalent 5.3125. There’s even a math function so a user could enter “5.5 * 25.4” and convert from inches to millimeters, or any other simple math function.
Other enhancements include a wire size converter, an Available Wire Sizes function that limits the program’s wire selection to those sizes and the ability to convert to fractional turns value for redesigns. For an overview of the ACRewind operation, for how to do searches of MotorDB or use MotorDB to do bare core designs, or how to use the ACRewind grid display to improve redesign selection, see the Tutorials available in the Resources -> Software section of EASA’s website at www.easa.com.
All of the enhancements are available in the current release of the program. To check if you have the latest release select Help -> About -> Installation details; the version number shown there should be 1.8.41.xxx or higher. Contact me at gvogel@easa.com if you need to update to the current version.
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