Motor Testing Made Easy 2002

Motor Testing Made Easy
Dr. Howard W. Penrose, Ph.D.

ALL-TEST Pro, A Division of BJM
Corp
Old Saybrook, Connecticut,
USA
Note: Use
browser back
ALL-TEST Pro July 2002
Arrow to return to CD
ROM selections.
About This Presentation

Intro to MTME and ALL-TEST Pro Capabilities
Case Studies
Hardware
Software
Accessories
Training
Consulting
How to Contact
ALL-TEST Pro Technology

Motor Testing Made Easy (M.T.M.E.)
You Cannot Afford to Be

Without an ALL-TEST
Benefits of ALL-TEST Pro Instruments
Rapid Training and Learning Curve!

ROI upon first fault detection!
Quickly implement a Preventive or Predictive
Maintenance Program with a Minimum Investment!
Include in Energy Programs! Reduce Energy Costs!!
Looking For Trouble?
Fault Detection
Turn Faults
Coil Faults
Phase Faults
Ground Faults
Cable Faults
Rotor Eccentricity
Broken Rotor Bars
Casting Voids
Capabiliti
es
AC/DC Motors
AC/DC Traction Motors
Generators/Alternators
Machine Tool Motors
Servo Motors
Control Transformers
Transmission & Distribution
Transformers
(Virtually Any Size)
CASE STUDIES
Case 1: Power Plant Phase

Unbalance
Current Unbalance -
9
B-C
A-C
8.8
8.6
8.4
Inductance
>11%
Phase Unbalance (ALLTEST III): 000,-016,-016
50 hp Delta Connected
Pump Motor
2 Replacements
Same Signature
Manufacturers
Production Decision =
$1 Million Customer
Loss
URG303201
Inductance Rotor test
A-B inductance
8.2
A-C inductance
B-C inductance
7.8
A-B
7.6
7.4
0
Rotor Position
10
11
12
Rotor Tests
Case 2: Rotor Bar

19.55
19.5
19.45
T1-T2
19.4
T1-T3
T2-T3
19.35
19.3
19.25
0
15
30
45
60
75
90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345
3000 hp Alternator
Rotor Analysis
400 hp, 2-Pole
Inductance
1.2
1.1
1
0.9
0.8
Position
10.5
9.5
8.5
7.5
6.5
0
Rotor Position
50 HP, 3600 RPM
10 11 12
42
Im pedance (400Hz)
Inductance (m H)
Impedance/Inductance
Rotor
41
40
39
38
37
36
35
1
Rotor Position
10
11 12
Winding Faults
Evaluation of Windings (Penrose

Theory of Winding Analysis)
Winding Shorts
Phase Angle and Current/Frequency
Response
Loose Connections
Resistance
Winding Contamination/Overheated
Inductance and Impedance
Rotor Condition and Severity

Inductance and Impedance Waveforms
Setting the Rules (MTME)

Phase Angle and I/F readings
Both Fi and I/F > +/- 2 Shorted Turns
Fi > +/- 1, I/F Balanced Shorted Coils
in the same phase
Fi Balanced, I/F > +/- 2 Shorted
Phase to Phase
Rules stand regardless of motor size

Resistance ~ +/- 5%
Setting the Rules (Cont.)

Impedance and Inductance
If impedance and inductance are
parallel, phase unbalance is most likely
due to rotor position
If impedance and inductance are not
parallel, phase unbalances are most
likely due to winding contamination or
overheated winding.
Setting the Rules (Cont.)

Inductive and Impedance Rotor Tests
Measurements of inductance due to rotor
position will present an idea of the
condition of a rotor due to casting voids
or broken rotor bars.
Measurements of impedance matched to
inductance provides a relative severity of
rotor condition.
Example 1: Bad 15 HP (Garlic Mill)
R
Z
L
Fi
I/F
Megger
T1-T2
0.954
52
20
80
-44
T1-T3
1.054
96
19
83
-39
>99M
T2-T3
0.9
56
22
85
-39
Garlic Mill Motor Condition

120
100
80
60
96
80
83
85
56
52
40
20
0
20
19
22
0.954
1.054
0.9
Phase 1
Phase 2
Phase 3
Resistance
Impedance
Inductance
Phase Angle
Equipment Size Limits? 8,000 hp, 200

RPM, 13.2 kV, Synchronous
Resistance
Impedance
Inductance
Phase Angle
I/F
Insulation
Position 2
T1-T2
0.322
189
37
81
-42
T1-T3
0.319
181
38
85
-49
#.#
Resistance
Impedance
Inductance
Phase Angle
I/F
Insulation
T2-T3
0.319
190
37
83
-46
T1-T2
0.318
190
37
83
-45
Position 1
T1-T3
0.316
192
38
86
-49
#.#
T2-T3
0.321
190
37
81
-44
Motor Circuit Analysis on a

Transformer?
Definition: An electric motor is a
transformer with a rotating secondary.

Evidence:
As rotor position is changed, the relative
winding ratios change.
Energy is induced into the secondary
which creates the magnetic fields
necessary to produce torque.
Transformer Test No. 1
Resistance
Impedance
Inductance
Phase Angle
I/F
Insulation
T1-T2
258.7
15654
24911
89
-36
T1-T3
77.04
11087
17645
90
-30
>99M
T2-T3
184.7
11043
17573
90
-6
Transformer Testing
Must ground all of the leads on other
side being tested
True sine wave generated by ALLTEST causes traveling currents that
provide erroneous results
Test same as 3-phase motor for 3phase transformers
Transformer Primary (2500kVA)

Reading
H1-H2
H1-H3
H2-H3
Resistance
3.703
3.623
3.648
Impedance
220
217
218
Inductance
87
86
86
Phase
Angle
I/F
88
88
88
-49
-49
-49
Good Readings
Transformers follow Penrose Theory of
Winding Analysis
Resistance: no more than 5% unbalance
above 0.250 Ohms and 7.5% below 0.250.
Impedance 5%
Inductance 5%
Phase Angle - +/- 1 digit
I/F - +/- 2 digits
Note: Readings that show a definite shift
should be flagged for further testing
Noisy Transformer
Resistance
Impedance
Inductance
Phase Angle
I/F
Insulation
T1-T2
0.02
1
0
18
-29
T1-T3
0.031
1
0
19
-33
#.#
T2-T3
0.041
1
0
18
-29
150 kVA Dry-Type 8-9 years in application

2nd Noisy Transformer
Identification of Defects
Resistance
Impedance
Inductance
Phase Angle
I/F
Insulation
T1-T2
0.053
1
0
19
-29
T1-T3
0.062
1
0
19
-29
2.202
T2-T3
0.082
1
0
19
-30
Hardware
ALL TEST PM/PdM and

Root-Cause-Analysis
Reliability
PM
RCA
Reliability
PM
PdM
RCA
ALL-TEST III Features

Impedance (Z) 5 - 1000 ohm
Inductance (L) 0.35 mH - 1.6 H
Capacitance (C) 100F - 50F
Phase Angle (Fi) 0 - 90 Degrees
Insulation Test 0 - 20 M, 1000
V
Frequency Range: 100, 300,
850, 2400 Hz
Dimensions: 7 x 3.75 x 1.75
Weight: 1.2 lbs
ALL TEST IV PRO Features

Stores over 500 motors with test results
Automatically compares stored references with
results
Automatically measures: Resistance;
Impedance; Phase Angle; Inductance; I/F; and
Insulation
Detects turn to turn faults at early stages
Includes Software for upload to PC and basic
trending
Light weight and hand held: 4.8 x 9.92 x 2,
< 2 lbs
Non-Destructive, Repeatable Testing
Safe Use
All test results in Engineering Units
Software
ALL-TEST IV PRO 2000

Software TREND 2000
Evaluation Software HAL Junior

2.0
ALL-TEST III Software

Condition Calculator 2.0
US Department of Energy
MotorMaster Plus
Query Screen MM+
EMCAT
Electric Motor Circuit Analysis

Tool
The Number 1 Software Tool
for Managing Your Electric
Motors and Transformers
Total Motor System

Maintenance and Management
in One Package
Import Past Data Collected

Using the Import Module
Upload Data from the

Set Up Routes
Schedule Maintenance
Analyze Motors Using

Proprietary HAL-gorithms
Trend Test Results Over

Time
Perform Rotor Test Using

Special EMCAT Grading System
Maintain Work Orders
Test DC Motors
Add Test Results from Other

Maintenance Equipment
Print Reports
Download Route to
EMCAT Features
Total Motor System
Develop Routes
Management in One Schedule
Package
Up/Down-load,
Import History,
Manual Data Entry
Print Detailed
Reports
Enter Data from
Other Technologies
Maintenance
Review Equipment By
Location and/or Name
Rotor Test
Evaluate and Trend
AC/DC Motors and
Transformers
Automated Analysis
Accessories
ATF-11 Armature Test

Fixture
M2000 Training Motor
Motor Circuit Analysis: Theory,

Application and Energy Analysis
book
Advanced Analysis Kit
Training and Consulting

Services
On-Site or Scheduled
Training
Consulting Services
Customization of Software
Data Analysis of MCA, vibration,
infrared and other technologies
Development of Maintenance
Programs
Other Motor System related
consulting services
Installation of Software
ALL-TEST Pro
A Division of BJM Corp
123 Spencer Plains Rd
Old Saybrook, CT 06475
Ph: 860 399-5937
Fax: 860 399-7784
Email: alltest@bjmcorp.com
Web: www.alltestpro.com

Motor Testing Made Easy 2002

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Motor Testing Made Easy

Dr. Howard W. Penrose, Ph.D.

About This Presentation

ALL-TEST Pro Technology

You Cannot Afford to Be

Benefits of ALL-TEST Pro Instruments

Rapid Training and Learning Curve!

ALL-TEST Pro July 2002

ALL-TEST Pro July 2002

Case 1: Power Plant Phase

Inductance Rotor test

ALL-TEST Pro July 2002

ALL-TEST Pro July 2002

Case 2: Rotor Bar

ALL-TEST Pro July 2002

50 HP, 3600 RPM

ALL-TEST Pro July 2002

ALL-TEST Pro July 2002

Evaluation of Windings (Penrose

Rotor Condition and Severity

Setting the Rules (MTME)

Rules stand regardless of motor size

Setting the Rules (Cont.)

Setting the Rules (Cont.)

ALL-TEST Pro July 2002

Example 1: Bad 15 HP (Garlic Mill)

ALL-TEST Pro July 2002

Garlic Mill Motor Condition

ALL-TEST Pro July 2002

Equipment Size Limits? 8,000 hp, 200

ALL-TEST Pro July 2002

Motor Circuit Analysis on a

transformer with a rotating secondary.

Transformer Test No. 1

ALL-TEST Pro July 2002

Transformer Primary (2500kVA)

ALL-TEST Pro July 2002

ALL-TEST Pro July 2002

150 kVA Dry-Type 8-9 years in application

2nd Noisy Transformer

ALL-TEST Pro July 2002

ALL-TEST Pro July 2002

ALL-TEST Pro July 2002

ALL TEST PM/PdM and

ALL-TEST Pro July 2002

ALL-TEST III Features

ALL TEST IV PRO Features

ALL-TEST Pro July 2002

ALL-TEST Pro July 2002

ALL-TEST IV PRO 2000

ALL-TEST Pro July 2002

Evaluation Software HAL Junior

ALL-TEST Pro July 2002

ALL-TEST III Software

ALL-TEST Pro July 2002

ALL-TEST Pro July 2002

Query Screen MM+

ALL-TEST Pro July 2002

Electric Motor Circuit Analysis

ALL-TEST Pro July 2002

Total Motor System

ALL-TEST Pro July 2002

Import Past Data Collected

ALL-TEST Pro July 2002