ALL-TEST Pro, LLC
Contents
1. 20 Chaneine the Motor Test Frequency e ne lak h as 21 V Additional Functions and Features eee tres toi Ee ene eite k ekere e eee kk K kk AA 22 Ele ctro Nlasrietic Interterence BM DE yyy b tte ere nette nasce usps 22 Rese UC tiie Ut SP MD b dixit eed Medusa dieat eost iudei osito 25 XT Chareme Yor ALL TEST PRO 3I nc nne salak x niyan kr k ya A na Pda dee di siepe 24 VII Data Interpretation Three Phase Motors sese 25 Data Interpretaton Tables ec a kay w ean tulo e alek 25 Additional Data Interpretation Considerations Three Phase Motors 26 Test 50 QULOTI SEN N DD DN DD etui caede aate 26 Rotor WMC GS sores d Meteo bad Nia bud se ant ur k En aa en 1 de Man duas 26 Confirming Suspected Winding S lOItS eese enn 26 Method 1 Rotor Compensa uit E Ho p PEU Kele atu eee 27 Method 2 Vartable Prequency Vests a an nk kl eti yaka AN Kak 27 ACTED DC Motor TeS 5ye naa yS abe Kare KON e mar weal ka KOR aA eke are K 20 2006 ALL TEST Pro www alltestpro com esting am Assembled DC NOt 2 ipe da s wan wa ERU epe aA ASAN 20 C LE 29 5eeData l l Ac E a e AA ek RA dut oeuf Quoc opo idiots 20 Compound or Shunt DG MOOR o siya eod ve reed p nero2. T lt ALL TEST PRO 31 ALL TEST Pro LLC ALL TEST PRO 31 User Manual Table of Contents Introdic toD MEE MESE M II DM Pee D SEE 4 USEC nap c cor T 5 Instrument Warnings and Considerations E deep tt bun sese e tm oe k k RE KAK K KA 5 General SatetvCoDsSTderattOTiss soot doses Ek Q r KE rde A l a n AN 5 AEESTEST PRO OLKi6COmnpOlCDIS 252 00 Ditta p k nn AG nip e eke k dro eoe Po deo K n KENARA 6 stromen O DOL aI LOT sai onion Ma perenne e 6 put Seton n Penn xarin anan di ka etu n k isan L a r diu efus b l a na in rad Ree 6 s Dr VS nell END TEE 7 Indie tor T5 lb Sec O Ke Ke Sate Sane eee teeter COE A LI eU EM AE 7 B hs oe Wage a az a SYN TTE PN 7 Keypad Ok e SOT T NA DIKE Xel a ea i e DR Haas a Pest Meads T r A IV Testing a Three Phase Induction Squirrel Cage MOtOFF E 9 Materials for Testing with the ALL TEST PRO 31 9 Windin Pe St NT 10 ERROR CODE S M 11 Phase Balance T eS sn K to eee EI NET ee 15 Insulation Resistance Lest O ci cay ken ove ede eed dn iu aure dp Eee edu WAN 17 RODE TO MH P E 19 E 19 Wave FONN W MM
3. This is the main menu 2 Connect the instrument leads to any 2 motor leads 3 Use the lt P to highlight the ROT icon from the display screen 4 Depress the ZERO OK key to perform the Bar Rotor Test 5 The screen displays Measuring Please wait Wait until the screen changes and the instruments issues an audible H beep before going to step 6 Note This may take several seconds 6 Turn the shaft by hand until the bar appears on the display screen This is display screen 4 7 Continue to rotate the shaft until a percentage value appears on the right side of the display screen _ 2006 ALL TEST Pro LLC 19 ALL TEST PRO 31 User Manual 8 To check the rotor condition a 9o Value Method i Turn the shaft until the bar is in the middle of the display screen ii Turn the shaft until the bar moves to the extreme left side of the screen note the displayed value ex 4 5 ili Turn the shaft until the bar moves to the extreme right side of the screen note the displayed value ex 4 7 IV Compare these values If they are with in 1 integer of each other the rotor doesn t exhibit any issues However values exceeding integer should be investigated further b Bar display method Turn the shaft one full turn if the bar hangs or hesitates at either end or in the middle there is a rotor issue and further testing should be performed Wave Form Test 1 While still in the Bar Tes
4. 31 requires ALL TEST PRO 31 Test leads and lead clips A pen and paper or a copy of the Motor Test Form on page 28 Testing can be performed directly at the motor at the nearest motor control center or disconnect For purposes of this manual we will test at the motor using an M2000 training motor this is for procedure only the M2000 is not designed to work with AT31 2006 ALL TEST Pro LLC 9 www alltestpro com ALL TEST PRO 31 User Manual Operating Procedure 3 Phase Motors Winding Test Measures and displays the winding impedance Z Phase Angle w Current Frequency response I F and Impedance phase balance 1 Label the three motor leads T1 T2 T3 It is very important to take the data in the same order for long term trending 2 Connect the Test leads to the Motor leads T1 amp T2 Note For quick trouble shooting the order of the readings is not important However for long term trending of the data should be preformed in the same CAR B order each time Optional Connect EN the Yellow lead to ground this is only j required for measuring insulation to ius ground Turn the instrument On Depress and hold the F1 ON key for 1 to 3 seconds This will bring up the main display screen Select the Motor Test 1 Using the Fl F2 keys highlight the winding test Icon ELM 2 Depress the Zero OK Key to select the Winding test Z w the main menu Obs
5. I F readings should be within one digit of each other Y Split the fields Evenly split the fields and compare the test results The Fi and readings should be within one digit of each other The DC armature can be evaluated using one of three methods Y Trend the overall armature circuit reading is trended over time The Fi and I F should not change more than one digit v Compare Compare the armature results from two similar DC motors see above to each other The Fi and I F readings should be within one digit of each other v Bar to bar testing The test results should show as a repeating pattern 2006 ALL TEST Pro LLC 30 www alltestpro com ALL TEST PRO 31 User Manual IX Additional Test Methods Wound Hotor Motors When testing a wound rotor motor the stator coils and rotor coils must be tested separately The procedure below must be followed or results will not be reliable When testing the stator coils the three phases of rotor coils must be shorted together and connected to an earth ground to bleed off circulating currents induced by the stator Data interpretation rules are the same as for induction motors as shown on page 25 Rotor coils are tested through the slip rings All three stator phases must be shorted together and grounded Once again data interpretation rules are the same as for induction motors as shown on page 25 Wye Delta Motors Wye Delta motors are often found on large chiller
6. Location Test Date Test Frequency BEEN FE 1 2 2 3 1 3 pov Phase Angle 5 66 66 Z Test or I F 45 Was rotor set to lowest value during phase balance test Y__ N__ Rotor test performed Y N Comments O ALL TEST PRO Continue with Last Phase Winding 3 Impedance amp Phase 1 2006 ALL TEST Pro LLC 13 www alltestpro com ALL TEST PRO 31 User Manual 9 Move the Test Leads to T1 amp T3 10 Read the Impedance Z and Phase Angle y values from display screen 1 for winding 2 Do not fill in the phase balance until all three phases have been measured 1 1 Depress the test key to display the Current Frequency Response I F 12 Record these test results on the motor test form Winding 3 Current Frequency 2006 ALL TEST Pro LLC ALL TEST Pro 31 Motor Test Form Motor ID Test Motor Location Warehouse Test Date 8 8 06 Test Frequency 200 Hz Phase Phase ti Phase 1 3 Impedance Z Phase Angle 6 Z Test or I F 45 Phase balance wi Test UmRessune 9 vous Was rotor set to lowest value during phase balance test Y UmRessune 9 vous Resistance Rotor test performed Y N Comments O ALL TEST PRO 14 www alltestpro com ALL TEST PRO 31 User Manual Phase Balance Test This calculates the impedance unbalance between phases This value can be used
7. Pass Fail Value Insulation systems prior to 1974 gt 1 Megohm 1 MegOhm per kV rating of motor Random Wound motors less than 600 V 5 MegOhms DC Armatures and Form Wound motors over 600 V 00 MegOhms 2006 ALL TEST Pro LLC 25 www alltestpro com ALL TEST PRO 31 User Manual Additional Data Interpretation Considerations Three Phase Motors There are three additional considerations when using an ALL TEST PRO 31 Test location Rotor windings Confirming winding faults Test Location If a fault is detected when testing from the motor control center motor disconnect or from any distance away from the motor through cabling it is important that a confirmation test be performed at the motor connection box prior to condemning a winding Note ALL TEST PRO MCA instruments will detect cable faults e If the readings are good at the motor during the confirmation test then the fault may be in the cable e If the reading improves but is still poor at the motor then there may be a fault in both the motor and cable e If the reading shows similar results at the motor then the fault exists in the motor Rotor Windings In the case of synchronous motors or generators that have windings in the rotor if a fault is detected with the ALL TEST PRO 31 rotate the shaft any amount and retest If the readings change or move with the repositioning of the rotor then the fault will most likely be found in the rotor windings If th
8. T2 T3 Fil 66 67 F 44 44 45 Method 1 Rotor Compensation One of the reasons for the result shown in Table 4 is a rotor anomaly such as severe casting voids rotor eccentricity etc To separate a rotor fault from a winding fault it is necessary to perform a rotor compensation Use the below procedure to perform the rotor compensation test 1 With the Instrument test leads connected to T1 amp T2 From display screen 1 turn shaft until the maximum impedance value is obtained 2 Read and record the impedance and phase angle reading from display screen 1 3 Depress the TEST button to read and record the I F value 4 Move the Test leads to T2 amp T3 turn the shaft until the maximum impedance value is obtained on this phase 5 Read and record the impedance and phase angle reading from display screen 1 6 Depress the TEST button to read and record the I F value T Move the Test leads to TI amp T3 turn the shaft until the maximum impedance value is obtained on this phase 8 Read and record the impedance and phase angle reading from display screen 1 9 Depress the TEST button to read and record the I F value The results should be 1 digit from the average Method 2 Variable Frequency Test The variable frequency test is used to confirm winding faults if the rotor is not accessible This often occurs if the test is conducted from a motor control center motor disconnect or the motor cannot be
9. Test button For a good capacitor the main display will show 90 or above A reading below 90 indicates a poor or failed capacitor Turn the instrument off 2006 ALL TEST Pro LLC 32 www alltestpro com ALL TEST PRO 31 User Manual X Tech Support and Information Technical support can be obtained by emailing or faxing your questions to ALL TEST Pro LLC Email support alltestpro com Fax 860 399 3180 Please put Attention ALL TEST PRO 31 Tech Support in your subject line XI Available Accessories for the ALL TEST PRO 31 ATF1100 DC Armature Test Fixture AT3402 4 Condition Calculator 3 0 Software AT3402 4PPC Pocket PC with Condition Calculator PPC 3 0 Software XII Training Class AT MCCLASS Motor Diagnostics Workshop Contact ALL TEST Pro LLC or visit www alltestpro com for class schedule ALL TEST Pro LLC 123 Spencer Plain Rd Old Saybrook CT 06475 Ph 860 395 2988 800 952 8776 Fax 860 399 3180 Web www alltestpro com 2006 ALL TEST Pro LLC 33 www alltestpro com ALL TEST PRO 31 User Manual ALL TEST Pro 31 Motor Test Form Motor ID Location Test Date Test Frequency Phase Phase Phase 1 3 Impedance Z Z Test or I F Phase balance opt Test Voltage Phase Angle D Ins Resistance Ins Resistance Rotor test performed Y___ Comments ALL TEST PRO Was rotor set to lowest value during phase balance test Y__ N__ ALL TEST Pro 3
10. aoc ND ves perdo pia YAN EN 20 ZArraat re DeStilig ouest uccide meer d heb rr rrr 30 DO MOtOE ADV SIS disnei del oe hu Had ea aita ded abut bab a y di hawak Saa da dod ya bab Feud dra Na k 30 IX Additionat TestAVIetliodSs vetus dentis eo tabe padecen duct de KA nudes eka e K r 3l Mound ROOD MOTOL sy 6ye ke an Wien et etie ra Mes Seatac c rises due dod etd N k 3l We B kU TOROS ZMA MA Ma dre dx a emat te e enu EIU dE 3l Capacitor LESUN c KA Dare E KO A W evek 32 X Tech Supportand InfotttattOfis2 kalan k k kh 33 XI Available Accessories for the ALL TEST PRO 31 33 PANE CIE CE ETE A UU SUL 33 PATENT PENDING 0401128 4 ALL TEST PRO 31 User Manual I Introduction The light weight hand held instrument can be used for immediate detection of winding shorts insulation to ground faults cable faults and more on AC DC electric motors transformers coils machine tool equipment linear motors and much more Testing can be performed at the motor connection box or from the disconnect or motor control center hundreds of feet away The ALL TEST PRO 31 AT31 is designed to provide simple test method e for troubleshooting faults e commissioning new and rebuilt machines e quality assurance in electric motors and other wound
11. current at 400 Hz is 45 lower than the current at 200 Hz The doubled test frequency is displayed in the lower right hand corner screen number 2 1s displayed in the upper right hand corner 3 To return to the Display Screen 1 depress the test key again which displays the impedance and phase angle measurement 4 Record the measured values on the 11 www alltestpro com ALL TEST PRO 31 User Manual ALL TEST Pro 31 Motor Test Form ALL TEST Pro 31 Motor Test Form Pro 31 Motor Test Form Motor ID Locion Continue with Other Phases Test Date T 5 Move the test leads to T2 T3 to est Frequency make the measurements on the next Phase Phase Phase p hase 2 2 3 E 3 Phase Angle Z Test or I F lr E Was rotor set to lowest value during phase balance test Y N__ Impedance Z Phase balance opt Rotor test performed Y___ N Comments ALL TEST Pro 6 Read the Impedance Z and Phase Angle y values from display screen 1 for winding 2 Do not fill in the phase balance until all three phases addi been measured 7 Depress the test key to display the Current Frequency Response I F 8 Record these test results on the motor test form Winding 2 Current Frequency Winding 2 Impedance amp Response 1 Phase 1 2006 ALL TEST Pro LLC 12 www alltestpro com ALL TEST PRO 31 User Manual ALL TEST Pro 31 Motor Test Form Motor ID
12. impedance measurement e The impedance values are less than 1 Q or greater than 999 2 5 e The Fi and or I F values are outside of the recommended tolerances See the Data Interpretation Section of this manual Select the Motor Test Using the Fl and gt F2 keys highlight the winding test Icon E 1 Depress the Zero OK Key to select the Winding test Z w from the main menu This will display the screen 1 2 While display screen 1 is displayed depress the F2 button the ALL TEST PRO 31 will emit an audible beep the 1 displayed in the upper left corner of the display screen will change to t Also the value of the frequency in the lower left hand part of the display screen1 In this case it is 200 Hz 3 Depress the A W buttons a The applied frequency will immediately change to the new value b The new impedance and phase angle Fi values will be displayed c The display screen number returns to 1 2006 ALL TEST Pro LLC 21 www alltestpro com ALL TEST PRO 31 User Manual 4 The ALL TEST PRO 31 frequency change is one step at a time To change to another frequency the steps 2 amp 3 must be repeated for each frequency Note The test frequency can only be changed from display screen 1 Changing the test frequency will also change the value V Additional Functions and Features Electro Magnetic Interference EMI Is electromagnetic radiation which is emitted by electr
13. the other end of the battery charging unit into the wall receptacle The supplied charger 1s universal and can be used for 120 240 V amp 50 60 Hz Simply attach the required adapter for the countries wall receptacle 3 When charging the charging indicating light will be illuminated red 4 The display screen will provide the instruments condition during the charge The data on the screen will identify information on the battery charge including length of time on charge battery voltage level and battery temperature 5 The battery charge indicating light will turn green when fully charged If the unit is not 2006 ALL TEST Pro LLC 24 www alltestpro com ALL TEST PRO 31 User Manual VII Data Interpretation Three Phase Motors The basic tolerances for the ALL TEST PRO 31 are the same as the ALL TEST IV PRO ALL TEST IV PRO 2000 and ALL TEST III superseded by the AT31 However the new AT31 platform is very sensitive and provides the ability to detect the more elusive pin hole shorts and other defects that have become prevalent with the widespread application of modern controls and electronics This requires some additional testing to verify the condition of a winding before making a pass fail decision Data Interpretation Tables During testing with the ALL TEST PRO 31 if a fault is detected using the interpretation tables review all of the additional data interpretation consideration before issuing a pass fail
14. to relate energy reliability and production cost avoidance potential to electric motor systems impedance unbalance The Impedance Unbalance Calculator IUC is available from ALL TEST Pro The concept of the IUC comes from Keeping the Spark in Your Electrical System An Industrial Electrical Distribution Maintenance Guidebook published by the US Department of Energy Bonneville Power Administration Pacific Gas amp Electric PacifiCorp and Tacoma Public Utilities As impedance varies with each phase the current Laity egy change cnin Art Motor Row tus Meme Lose Dope cac nor Size INI Em mm Ease 57 Ses Orio Eaters yr in each leg of the motor varies This esvots dian ive CREE Bane yr See Grigas generates increased losses in the Eanes form of heat Heat reduces both insulation life and the life of the lubricant The Impedance Unbalance eren erani manena Calculator is available from ALL TEST Pro 1 Leave the Test leads on T1 amp T3 2 Set the reference p to zero This establishes 11 13 as the reference 3 Turn the motor shaft until the highest impedance value is obtained 4 Depress the ZERO Key This sets the reference phase T1 T3 to ZERO 0 Enter 0 on the Motor Test D Form 5 Move the Test leads to T2 amp T3 This determines the Impedances Phase Balance or Unbalance Referenced to 11 15 2006 ALL TEST Pro LLC 15 www alltestpr
15. uncoupled 2006 ALL TEST Pro LLC 27 www alltestpro com ALL TEST PRO 31 User Manual Reduce the test frequency follow the procedure for changing the test frequency and re test Example 1 If the test results remain similar meaning that the actual readings will change by a few digits but the difference between the readings remains the same then the winding is good as in Table 5 In table 4 the test spread of the Fi is 3 units 66 to 69 at the lower frequency see table 5 the Fi values changed from 70 to 73 the spread is still 3 units This a good winding Table 4 Sample Test Results TI T2 T1 T2 TI T3 T1 T3 12 13 Fo 66 67 co F 44 44 45 Table 5 Adjusted Frequency Sample Good TI T2 TI T3 T2 T3 F 70 7 73 F 44 44 45 Example 2 If the test results at the lower frequency separate more then the winding is in poor shape In table 4 the test spread of the Fi 1s 3 units 66 to 69 at the lower frequency see table 6 the Fi values changed from 70 to 75 the spread has increased to 5 units This winding is in poor shape Table 6 Adjusted Frequency Sample Bad tpt ee Fil 70 IF 45 45 2 z One of the main purposes for varying the frequency is to find a pin hole short This type of short generally occurs in the end turns of a motor winding T
16. 00 amp 1000V 7 Depress the test key and hold until the display shows 0 MQ This is to verify the test leads are connected to a good ground 2006 ALL TEST Pro LLC 8 Move the Red test lead to any motor lead Standard Insulation Resistance measurements instruments require testing all 5 leads this is not necessary with the ALL TEST PRO 31 since it is more than just an Insulation Resistance measuring device 9 Depress the test key and hold until 500 MQ is displayed If the ALL TEST PRO 31 does not display 500 MQ after one minute of testing stop and record value and test voltage on the motor test form 10 Depress the MODE key to return to the Main Display Screen Motor ID Test Motor Location Warehouse Test Date 8 8 06 Test Frequency 200 Hz Phase 1 2 Impedance Z 107 PhaseAngle 66 Z Test or I F 45 Ins Resistance 25500 ALL TEST PRO 31 Motor Test Form Phase balance opt 2 Phase Phase 2 3 107 66 as 45 Test Voltage 500 Was rotor set to lowest value during phase balance test Y Rotor test performed Y___ N Comments ALL TEST PRO 18 www alltestpro com ALL TEST PRO 31 User Manual Rotor Test Squirrel Cage Induction motors operate on the magnetic inductance principle The rotor bars provide the path for the current to flow on the rotor The current flow through the rotor bars creates a magnetic field which in turn c
17. 1 Motor Test Form Motor ID Location Test Date Test Frequency Phase Phase Phase A C Impedance Z Z Test or I F Phase balance opt Test Voltage Phase Angle ID Ins Resistance Ins Resistance Rotor test performed Comments ALL TEST PRO Was rotor set to lowest value during phase balance test Y__ N__ BACK TO TOP 2006 ALL TEST Pro LLC 34 www alltestpro com
18. DING Series Motor Connect the instrument test leads to Al amp S2 record and trend Impedance Phase angle and I F Impedance reading will vary with temperature and is important that comparative reading are taken at the same temperature If the impedance is decreasing with time the armature winding are either contaminated or degrading Changes in phase angle and I F signify winding shorts See Data Interpretation section ASSEMBLED 1 Connect the instrument test leads to the Al and A2 armature leads 2 Lift all but two of the DC motor brushes 90 degrees from each other 3 Select the Motor Test from the main menu see Winding Test section 4 Adjust the test frequency until you are between 1 and 999 Ohms of impedance 5 Position the leading edge of one of the brushes at the edge of one rotor bar Note the impedance and phase angle values Repeat step 6 until you have completed one full revolution 7 If the impedance values are consistent and or repeating the armature is good If not there is a short Note This test can also be performed using I F Screen 2 and Deviation Screen 3 DC Motor Analysis DC field coil analysis 1s performed by using one of three methods v Trend Trend the windings over time or compare to a past reading The Fi and readings should be within one digit from the baseline reading Y Compare Two similar DC motors same manufacturer and model can be compared to each other The Fi and
19. EST Pro sales support for a replacement reset key To reset units with the reset button serial number 2029 amp above 2006 ALL TEST Pro LLC 23 www alltestpro com ALL TEST PRO 31 User Manual The latest release of the ALL TEST PRO 31 serial numbers 2029 and higher have an internal reset button located on the top of the ALL TEST PRO 31 To reset the unit if it locks up simply depress the reset button M below in yellow using a paper clip pen tip or some other small device VI Charging Your ALL TEST PRO 31 CAUTION The supplied charger is an integral part of the charging circuit Using any other charger will destroy your AT31 and will void any warranty If the supplied charger becomes lost or defective contact ALL TEST Pro sales support for a replacement The installed batteries are not subject to retained memory and to insure the ALL TEST PRO 3 1s fully charged leave it plugged into the charging unit when not in use A fully charged battery should last about 8 hours The operational time can vary depending on the number of insulation to ground tests performed on a single battery charge The more Insulation resistance tests the shorter the operational time Jf the ALL TEST PRO 31 is not continuously left on trickle charge it should be charged at least once a month To charge the ALL TEST PRO 31 1 Plug the battery charging unit into the battery charging port on the top of the ALL TEST PRO 31 2 Plug
20. LL TEST Pro LLC 22 www alltestpro com ALL TEST PRO 31 User Manual 1 Using the buttons select EMI from the main menu 2 Depress the Zero OK Key to select the EMI test 3 The ALL TEST PRO 31 display screen instructs the operator to short the test leads together These are the red amp black lead and depress the Zero OK key This calibrates the ALL TEST PRO 31 to 0 4 The testing light will illuminate and 0 0 mV will be displayed on the screen This is display screen 9 5 Connect the winding test leads to the winding or machine that is being tested If any EMI is present the values that are displayed are the low and high values of the EMI peak amp valleys being detected 6 Depress F2 button to toggle between the low amp high EMI value Resetting the Unit On occasion the ALL TEST PRO 31 may fail to respond to key board or lock up due to excessive EMI present or other reasons Sometimes the unit may lock up during normal operation If this occurs on units with a serial number 2028 and lower a reset key is included in your kit To reset the unit using the included accessory reset key serial 2028 amp below 1 Remove the test leads and plug the reset key into the test lead 15 pin DB connector 2 The ALL TEST PRO 31 will be reset to the main menu 3 Remove the reset key and replace in the ALL TEST PRO 3 carrying case Do not misplace the reset key however if lost contact ALL T
21. auses the rotor iron to become a very strong electro magnet If these rotor bars become open or broken current will not flow properly through the rotor bars This causes unbalanced magnetic forces applied between the rotor and the stator The ALL TEST PRO 31 provides a feature that performs 2 unique quick rotor tests to determine if any rotor issues are present in an assembled induction rotor Rotor issues such as broken or loose rotor bars casting voids in the cast aluminum rotors eccentrically machined rotors and high resistance connections are some of the rotor issues easily recognized by the ALL TEST PRO 31 Bar Test Provides a visual real time indication of the response of the rotor to the energized stator filed Waveform Test Provides an additional visual indication of the change in response of the rotor to the energized stator field in the shape of a time wave form Both rotor tests send a low voltage AC sine signal through the stator winding manual rotation of the shaft induces a voltage into the rotor bars The ALL TEST PRO 31 displays the interaction between these 2 magnetic fields A good rotor should provide smooth symmetrical and repeatable display Induction rotors with issues will provide erratic distorted displays Additional tests are recommended to assist in determining the exact cause of the rotor issue Bar Test 1 Using the ON key or the MODE key from the keypad section to navigate to the display screen
22. d of testing this type of motor 1s by trending looking for changes particularly I F and phase angle Fi Testing Series Field 1 Connect the instrument test leads to motor series field leads S1 amp S2 2 Select the Motor Test from the main menu see Winding Test section 3 Adjust the test frequency to get the impedance value above 1 Ohm and below 999 Ohms 4 Record the test frequency impedance and phase angle readings 5 Compare these results to series field readings from a similar motor or to a baseline reading on the same motor and note any changes Testing the Armature Field See the Armature Testing Section Below See Data Interpretation Compound or shunt DC motor Testing Shunt Field 1 Connect the instrument test leads to shunt field connectors F1 amp F2 2 Select the Motor Test from the main menu see Winding Test section 3 Adjust the test frequency to get the impedance value above 1 Ohm and below 999 Ohms 4 Record the test frequency impedance and phase angle readings 5 Compare these results to readings from a similar motor or to a baseline reading on the same motor and note any changes Testing the Armature Field See the Armature Testing Section Below 2006 ALL TEST Pro LLC 20 www alltestpro com ALL TEST PRO 31 User Manual Armature Testing DC armatures are time consuming but relatively easy to test There are three basic methods of testing DC armatures e Trending e Assembled e Disassembled TREN
23. e readings remain the same then the fault is most likely in the stator In addition to the recommendations from the next section See page 25 for special test methods for wound rotor motors Confirming Suspected Winding Shorts One of the unique features of the ALL TEST PRO 31 is the ability to manually adjust the test frequency to 100 Hz and below The ALL TEST PRO 31 is very sensitive to winding shorts at100 Hz and below The ALL TEST PRO 31 default test frequency is 200 Hz The default frequency of 200 Hz was selected based upon experiment to reduce the chances of false positives This frequency is adequate for most testing If a winding tests good at 200 Hz then that winding 1s generally in good condition However if it tests badly based on the above data interpretation table then it should be retested at a lower frequency to confirm the fault This is very important as the lower frequencies will amplify winding shorts for improved sensitivity And due to this sensitivity it is necessary to 2006 ALL TEST Pro LLC 26 www alltestpro com ALL TEST PRO 31 User Manual confirm winding shorts before making a repair decision As such there are two methods for confirming a winding fault condition a Rotor compensation test b Variable frequency test The test results such as those found in Table 4 at 200 Hz indicate a potential winding fault Fi is out by more than 1 from average Table 4 Sample Test Results TI T2 TI T3
24. equipment The patented tests performed for early winding fault detection e winding impedance test e phase angle e I F current frequency response tests e EMI Electro Magnetic Interference test for detection of low level EMI currents that can affect readings and may be the result of other faults within the motor circuit Note The ALL TEST PRO 31 provides real time measurements of the on going test When combined with the ALL TEST IV PRO 20000 provides the most comprehensive off line motor analysis system available at any price Insulation Resistance to ground To prevent electrical shocks and to assure safety of personnel the AT31 provides an insulation to ground test The insulation resistance test provides either 500 or 1 000 Vpc to measure the insulation resistance up to 500 Meg Ohm For winding with voltages rated up to 60004 2006 ALL TEST Pro LLC 4 www alltestpro com ALL TEST PRO 31 User Manual II Safety CAUTION The AT31 is designed to test de energized equipment safely and quickly Improper application of the AT31 on live circuits 1s a danger to the user and will result in the destruction of the testing circuit requiring instrument replacement Instrument Warnings and Considerations The ALL TEST PRO 31 is a CE registered instrument The following is a list of considerations for equipment life and accurate data collection A Ensure that all power has been removed from the circuit being tested including
25. erve Record the Test Data 1 The default value is 200 Hz as displayed in the bottom right corner of the display screen a The value of the impedance should be between 1 and 999 If the Z is less than 1 or greater than 999 Q change the test frequency of the winding test see Changing the Motor Test Frequency b The current frequency response value I F must be between 15 and 50 if it is not change the frequency of the winding test c If the phase angle Fi is less than 15 change the winding test frequency 2006 ALL TEST Pro LLC 10 www alltestpro com ALL TEST PRO 31 User Manual Note If any of the measurements fall outside the above ranges the test 1s not valid 2 Display screen 2 displays the results of the current frequency test To view display screen 2 depress the Test key Display screen 1 Displays the measured impedance in ohms 107 phase angle in degrees 66 and the frequency of the winding test 200 Hz The screen number 1 is displayed in the upper left hand motor test form ERROR CODES If the impedance readings are out of range an error code will be displayed on the measurement screen E1 error code means the impedance value is greater than 1000 ohms E2 error code means the impedance value is greater than 10 000 ohms 2006 ALL TEST Pro LLC Figure 2 Display Screen 1 Display Screen 2 Displays the results of the Current Frequency I F response test 45 the
26. es rated up to 6000V NOTE The following tables provide the recommended voltages and Minimum Insulation Resistance to ground values If these values differ from your equipment manufactures follow their guidelines Insulation Resistance Test Voltage Motor Voltage Rating Insulation Test Voltage 600 Volts AC 500 V 600 to 6000 Volts AC 1 000 V Insulation Resistance Values IEEE 43 2000 Application Insulation systems prior to 1974 gt 1 Meg Ohm 1 Meg Ohm per kV rating of motor Random Wound motors less than 600 V 5 Meg Ohms DC Armatures and Form Wound motors over 600 V gt 100 Meg Ohms 1 Using the ON key or the MODE key from the E d keypad section to navigate to the display screen This is the main menu 2 Use the lt Pto highlight the INS icon from the display screen This sets the ALL TEST PRO 31 up to measure the insulation resistance to ground 3 Depress the ZERO OK key to perform the Insulation Resistance i Test This displays screen 4 Connect the both the Red lead amp the Yellow lead to ground the insulation resistance test screen 5 View the insulation test voltage selected upper right hand corner of the insulation resistance display screen Refer to the insulation resistance test voltage table above for the correct voltage 2006 ALL TEST Pro LLC 17 www alltestpro com ALL TEST PRO 31 User Manual 6 Depress the F2 key to toggle between 5
27. hese faults were uncommon prior to the 1990 s but have become more common following the increased application of Pulse Width Modulated PWM drives These shorts occur in a very small area between individual turns in a coil They can cause the motor to trip on a Variable Frequency Drive VFD but often will continue to operate when the voltage 1s applied directly across the line such as if the VFD 15 placed in bypass 2006 ALL TEST Pro LLC 28 www alltestpro com ALL TEST PRO 31 User Manual VIII DC Motor Testin Electrical testing of DC motors is a challenge the ALL TEST PRO 31 can provide some limited troubleshooting capabilities for DC motors For a more detailed and thorough analysis the ALL TEST IV PRO 2000 should be used One of the key issues is the inability to compare like coils However it is possible to do some limited comparisons of coils if the information is available trending changes over time is also possible and measuring amp trending insulation resistance to ground of both the field and the armature windings Testing an Assembled DC Motor Connect the ALL TEST PRO 31 s ground lead yellow lead to an earth ground at the test point Series DC motor DC series motors provide a special problem since the series field 1s constructed of a few turns of very large wire to handle the high current through the armature and field This combination provides a very low impedance value The best metho
28. ical circuits carrying rapidly changing signals as a by product of their normal operation and which causes unwanted signals interference or noise to be induced in other circuits This interrupts obstructs or otherwise degrades or limits the effective performance of those other circuits NOTE These voltages can come from cables of other energized machines lying in the same cable tray as the cables for the machine being tested The EMI feature of the ALL TEST PRO 31 measures if there is any EMI present in the motor system which will cause errors in ALL TEST PROG 31 or ALL TEST IV PRO 20007 readings EMI causes non repeatable or unsteady test results A constantly changing value for impedance during testing indicates either the shaft is still rotating or there is EMI present from another cable EMI is a floating voltage which will often have a value above the ground reference 0 Volts The EMI may be sinusoidal depending upon the cause for the EMI see Figure 3 EMI values over 1 Volt should be investigated and corrected whenever possible HI values above 10 milli Volts may interfere with test results If the impedance values are constantly changing 1 verify that the rotor of the motor being tested is not turning 2 4 Test for EMI using the following procedure Figure 3 Electro Magnetic Induction 0 4 milli Volts 0 2 milli Volts 0 Volts Additional research is being performed to provide recommended limits 2006 A
29. ly charged F Test indicator light Light is illuminated green when the unit is testing G Insulation Test indicator light The light illuminates ye ov when the instrument is testing insulation resistance Caution Applied voltage is 500 or 1 000 Volts DC Display Screen The display screen on provides the AT 31 with individual icons to select and perform the various motor winding tests 7 Icon Performs Impedance Z Phase Angle y Current Frequency I F and Phase Balance tests used for winding shorts I ROT Icon Performs the Rotor test used to find squirrel cage induction motor rotors faults E INS Icon Performs the Insulation to ground resistance test selection used to verify that the insulation to ground resistance is sufficient to prevent electrical shock K Battery charge level indicator fully charged battery will have 7 bars It is recommended to keep the AT31 on charge when not in use to ensure proper operation 2006 ALL TEST Pro LLC 7 www alltestpro com ALL TEST PRO 31 User Manual L PWR OFF Icon turns the instrument off The AT31 will automatically shut off after about 5 minutes M EMI Tests for EMI signals within the Motor System that could cause errors in the AT31 test results Keypad Section The keypad section provides keys to operate and control the ee functions of the AT31 N Up direction and MODE button returns the AT31 display screen to
30. o com ALL TEST PRO 31 User Manual 6 Turn the shaft slowly until the lowest percentage value 1s obtained The value should be less than 3 values of phase unbalance gt 5 indicate a fault in the winding and should be investigated further ALL TEST PRO 31 Motor Test Form Motor ID Test Motor Location Warehouse Test Date 8 8 06 Test Frequency 200 Hz 22 Phase l 1 2 7 Record this value on the motor test RETI 197 form for Phase 2 3 In this case the x he xn Phase Angle 66 value is 0 Z Test or I F 45 Phase balance opt Ins Resistance ooe Was rotor set to lowest value during phase balance test Y__ N__ Rotor test performed Y N Comments ALL TEST PRO 8 Move the test leads to T1 T2 this checks the 4 9 y Impedance Balance Unbalance of Phase of the 7 n final phase winding TI T2 to TI T3 10 Record this value on the motor test form for Phase 1 2 In this case the value is 27 which is acceptable Refer to the Data Interpretation Section of this manual for Acceptance criteria 2006 ALL TEST Pro LLC 16 www alltestpro com ALL TEST PRO 31 User Manual Insulation Resistance Testing To prevent electrical shocks and to assure safety of personnel the AT31 provides an insulation to ground test The insulation resistance test provides either 500 or 1 000 Vpc to measure the insulation resistance up to 500 Meg Ohm For winding with voltag
31. on the winding tested When making repair replace decisions it is also important to evaluate the specifics of the application Is the motor in a critical application what are the operating conditions environment etc Table 1 Three Phase Motor Test Results Test Limits Description Impedance Special This result can be used to trend the condition of a winding If the overall readings decrease significantly between tests then the winding is degrading or contaminated Phase Angle Fi 1 point Fi is a winding short indicator A result of 35 36 37 degrees is OK a result of 35 32 32 would be a fault shorted winding This value should be greater than 15 degrees Current Frequency 2 points I F is a winding short indicator A result of 44 45 46 would be I F OK 44 46 46 is borderline and 42 45 45 would be a fault shorted winding These readings should be between 15 and 50 Phase Balance 5 Indicates winding unbalance which will result in current unbalance motor heating and poor starting It is recommended that this value remains under 3 with 5 indicating a fault Insulation See Table 2 and Indicates ground wall insulation failure or severe winding Resistance 3 contamination Table 2 Insulation Resistance Voltage Motor Voltage Rating Insulation Test Voltage 600 Volts AC 500 V 600 to 6000 Volts AC 1 000 V Table 3 Insulation Resistance Values IEEE 43 2000 Application
32. s as well as in other applications They will have six leads numbered T 1 through T 6 all running to the motor control center When testing this type of motor use the following connection sequence Phase 1 T1 to T4 Phase 2 T2 to T5 Phase 3 T3 to T6 Note that testing T1 T2 and T3 etc as with induction motors will normally show open phases no continuity Megohm testing should be performed on each of the three phases Data interpretation rules are the same as for induction motors as shown on page 20 2006 ALL TEST Pro LLC 3l www alltestpro com ALL TEST PRO 31 User Manual Capacitor Testing Note This is a Pass Fail test Motor starting capacitors and power factor correction capacitors can be effectively tested with the ALL TEST PRO 31 This test will not provide the capacitance value of the test specimen but will indicate if the capacitor is performing properly in an AC Circuit l gt Turn Line power off Disconnect one capacitor lead from the circuit Short the capacitor terminals to remove any remaining charge Put the ALL TEST PRO 31 in winding test mode by selecting the motor icon from the mode screen Connect the red and black test leads to the capacitor An impedance value should be displayed If impedance value shows the capacitor is open Observe the phase angle measurement in the upper right of the display If the capacitor is good this number is very close to 90 Press the
33. static power stored in capacitors Discharge all capacitors being tested Attaching the AT31 to live voltage will destroy the unit and void the warranty e Do not attempt to change the batteries Contact your distributor of the AT31 ALL TEST Pro at 860 395 2988 or via email sales alltestpro com to have the battery pack replaced e Do not open the instrument Electrostatic charges may damage surface mount electronics Please contact your vendor or ALL TEST Pro authorized repair center e Use only the supplied charger for charging the instrument It is an integral part of the charging circuit Using the wrong charger will damage your instrument General Safety Considerations Following are general safety considerations for using the AT31 motor tester A The AT31 is an off line motor tester All power and residual power must be disconnected It provides a safe method of testing your electric motors A Folow all safety rules of your company and OSHAct or country equivalent for off line testing methods including appropriate Personal Protective Equipment PPE Improper or unsafe operation of the equipment is the sole responsibility of the user For MCA testing the AT31 sends out a low voltage high frequency signal not harmful to the technician or most electronic equipment variable frequency drives and soft starts However electronic equipment and personnel must observe appropriate safety considerations disconnect electronic equipmen
34. t when performing the insulation to Ground resistance test Meg Ohm test 2006 ALL TEST Pro LLC 2 www alltestpro com ALL TEST PRO 31 User Manual III ALL TEST PRO 31 Kit Components Figure 1 AT 31 Kit ALL TEST PRO The AT31 kit contains all of the necessary components necessary to test most electrical machinery ALL TEST PRO 31 instrument Batteries installed Test leads and clips Charger 115 or 230 Volt Manual on CD Rom Carrying Pouch e Reset Key On units before Serial number 2029 Instrument Operation The instrument is divided up into three working areas 1 Input Section 2 Display Area 3 Keypad Input Section The input section provides all the external connections to the ALL TEST PRO 31 Test lead port Charger port Ground test lead port for Insulation to Ground Measurements Reset Button Serial number 2029 and higher now 2006 ALL TEST Pro LLC 6 www alltestpro com ALL TEST PRO 31 User Manual Display Section The display section 1s divided into 2 sections 1 Indicator Lights FEST OBJECT 2 Display Screen LU AU The Indicator Lights section informs the operator when an operation or test 1s being 1 performed The Display screen allows the operator to select tests to be performed by the AT31 Indicator Light Section E Charging light Indicates that the unit 1s charging light is illuminated red while charging light is green when ful
35. t Screen display screen 4 depress the 7 button EAR 2 A line will be displayed across the screen Begin to turn the shaft the faster the shaft turns the more waveforms 3 are displayed adjust the speed until 4 or 5 complete waveforms are displayed 3 After several seconds the waveform will lock 1n place This will be accompanied with an audible beep 4 The waveform should be smooth and repeating with well rounded peaks on the wave forms 5 Non repeating or flat peaks on the waveform indicate a rotor issue 6 Depress MODE button to return to the Main Screen 7 From the Main Screen use lt P to select PWR OFF 8 Depress the button to turn the ALL TEST PRO 31 off 2006 ALL TEST Pro LLC 20 www alltestpro com ALL TEST PRO 31 User Manual Changing the Motor Test Frequency The default testing frequency for the ALL TEST PRO 31 is set at 200 Hz This test frequency should be good for the majority of winding tests However there are a few instances where a different frequency may be required The ALL TEST PROQ 31 allows the user to select a test frequency of 25 30 50 60 100 200 400 or 800 Hz The test frequency selected is not dependent on the frequency of the applied voltage to the winding It is more dependent on the instrument making a valid measurement Note Increasing the test frequency will increase the impedance measurement Reducing the test frequency will decrease the winding
36. the main menu O On and left direction F1 button turns the 413 1 on and moves the curser across the display screen toward the left P Zero and Selection OK button selects which test to perform and provides reference selection to calculate 9o differences Q Down direction and Test button toggles between display screens performs selected tests R Left F2 and Hz button allows the operator to change the test frequency for the moves the cursor winding test and moves the cursor across the display screen to the right Instrument Test Leads The ALL TEST PRO 31 uses a 15 pin DB connector for winding testing The red test lead 1s the output and the black test lead 1s the return For Insulation testing the yellow test lead should be connected to ground 2006 ALL TEST Pro LLC 8 www alltestpro com ALL TEST PRO 31 User Manual IV Testing a Three Phase Induction Squirrel Cage Motor Testing can be performed from the motor control center disconnect or at the motor itself This instruction is provided to demonstrate all of the features of the ALL TEST PRO 31 which can also be used to evaluate other types of electric machines Note The M2000 demo motor is used in this manual for procedural purposes only it is not designed to work with the ALL TEST PRO 31 Materials for Testing with the ALL TEST PRO 31 Figure 2 Equipment and Materials To perform a motor test with the ALL TEST PRO
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