- 01IncomingEvery lot, to its IS standard
- 02In-processMachined parts to drawing
- 03Stator & rotor100 % before assembly
- 04Routine testEvery motor, 100 %
- 05Type testEvery new design
Level 1 · every motor
The routine test record you receive.
Under our final inspection plan EM-QA-FT-03-03, every motor gets five electrical tests to IS 15999 and IS 12615 and a final inspection to IS 1231 and IS 2223, recorded on a final inspection test certificate with QA seal.
Level 2 · every new design
- Stator resistance, insulation resistance and high-voltage test
- No-load and reduced-voltage tests
- Load test at 25, 50, 75, 100 and 110 % on the dynamometer
- Pull-out and pull-up torque
- Momentary overload
- Temperature rise
- Locked-rotor test
- Noise and vibration
- To IS 15999 and IS 12615, criteria EM-DD-FT-15
Level 3 · every 60 Hz order
- 60 Hz test certificate
- SF 1.25 proven by heat run at type test
- Type test report supplied at first-article approval
| Check | Method | Result |
|---|---|---|
| Stator resistance | Resistance meter · to winding data sheet | PASS |
| Insulation resistance | Megger | PASS |
| High-voltage test | HV tester | PASS |
| Reduced-voltage test | Test panel | PASS |
| No-load test | Test panel · current and power | PASS |
| Serial number, finish | Visual | PASS |
| DE / NDE taps, keyway | Gauge, micrometer | PASS |
| Nameplate, earth, mounting | Visual · no damage | PASS |
Incoming materials
What goes into an EMPD motor.
Every lot is checked on arrival under our incoming raw material plan EM-QA-FT-03-01 and recorded on a goods receipt and inspection note. All raw materials are sourced in India.
| Part | Material | Standard | Incoming check |
|---|---|---|---|
| Cast-iron bodies and covers | Grade FG 200 | IS 210 | Tensile strength, Brinell hardness and chemistry from test certificate; visual; dimensions |
| Aluminium bodies, covers and terminal boxes | LM6, ADC12, LM20 | IS 617 | Chemistry from test certificate; visual; dimensions |
| Electrical stampings | Silicon steel 50C400 to 50C1000, 0.35 / 0.5 mm | IS 648 | Grade, thickness, OD / ID, slots, core length, watt-loss per kg at 1.5 T |
| Enamelled copper wire | Class F 155 °C or H 180 °C, grade 2 | IS 13730-0-1 | High-voltage withstand min. 4 kV, diameter, appearance; 100 % on magnet wire |
| Die-cast rotors | Aluminium 99.6 %, EC grade | IS 617 | Rotor OD and ID, core length, growler test |
| Shafts and keys | EN8, EN8D, EN19, EN24, SS410, 16MnCr5 | IS 1570-5 | Brinell hardness and chemistry from test certificate; diameter, length |
| Bearings | Ball and roller, ZZ / 2RS | Make and series to order | OD, ID, width, damage |
| Insulation paper and sleeving | Class F and H | IS 12316 | High-voltage test (paper 4 kV, sleeve 2 kV), thickness |
| Varnish | Class F and H | IS 10026 | Class and shelf life, every lot |
| Lead wire | Fibreglass, PTFE or silicone insulated | IEC 60228 class 5 | Cross-section, 0.5 to 2.5 mm² |
Mill test certificates are reviewed and signed off by a quality engineer before a lot is released to production.
From our test bay
Real reports. Real numbers.
Two reports exactly as they left our lab, with customer names, supplier names and signatures removed.
- 1No-load test, run with the brake fitted
- 2Locked-rotor current, power and torque
- 3Winding resistance and PT100 / PTC sensors
- 4Insulation resistance at 500 V DC, in GΩ
- 5High-voltage test at 2.4 kV
- 6Noise level
- 7Brake air gap, go / no-go gauge
- 8Brake torque and noise before and after 10 on / off cycles
- 9Rotation check, clockwise and counter-clockwise
Type test · every new design
0.37 kW 2-pole IE3
690 V · Class H · 60 °C ambient · report ETR 25-26 093, January 2026
A customer-specific design: 690 V, 60 °C ambient and service factor 1.00 to the customer’s specification. Standard EMPD three-phase motors are SF 1.15 at 50 Hz and 1.25 at 60 Hz.
- Locked-rotor current533 %Limit ≤ 700 % of rated · PASS
- Locked-rotor torque382 %Limit ≥ 170 % of rated · PASS
- Pull-out torque461 %Limit ≥ 160 % of rated · PASS
- Winding temperature rise44 KLimit ≤ 125 K, Class H · PASS
- Noise at 1 m61 dBLimit ≤ 84 dB · PASS
- Vibration, worst axis0.60 mm/sLimit ≤ 1.8 mm/s · PASS
Also passed: insulation 2.96 GΩ (≥ 30 MΩ), high voltage 2.38 kV for 60 s, 1.6 × torque overload for 15 s, and start at reduced voltage in both directions.
Request the report for your motorThree inspection plans
Nothing moves on until it passes.
- 1Incoming EM-QA-FT-03-01 · Every lot, to sampling plan
Castings, stampings, copper, shafts, bearings and insulation checked against their IS standard; mill test certificates reviewed by a quality engineer. - 2In-process EM-QA-FT-03-02 · To sampling plan
Bodies, end covers, shafts and rotors measured against the drawing: bores, seatings, PCD, bearing fits, key dimensions and run-out. - 3Wound stator EM-QA-FT-03-03 · 100 %
Overhang, surge comparison, high voltage, insulation and resistance, stator OD and core length, visual. - 4Rotor EM-QA-FT-03-03 · 100 %
OD, bearing seats after grinding, length, dynamic balancing, run-out, keyway symmetry and taps. - 5Final motor EM-QA-FT-03-03 · 100 %
Routine test, then serial number, finish, DE / NDE taps, keyway, nameplate, earth provision, mounting position and damage.
174 measuring instruments, 74 electrical and 100 mechanical, are calibrated every year by an external laboratory (instrument list EM-QA-FT-13).
Standards
Built and tested to
Certificates & approvals
Audited by others.
Tap a certificate to view the copy. Check our BIS licence CM/L-6500033304 yourself on the BIS Care app or at manakonline.in, under “Search a licence”. To verify ISO certificate IND.25.2440/IM/U, contact Bureau Veritas India: +91 22 6274 2000, [email protected]. ISO 9001 since July 2015; ISO 14001 and 45001 since November 2025.