User Manual - PMC Rentals
Contents
1. YES IND120217A1 and IND120217B1 higher Firmware version is listed under the SET Icon in the Main MENU If NO is selected then the display will sequence to the Insulation to Ground Test If YES is pressed then a message screen during the DF and Capacitance measurements will appear displaying Measuring DF amp Cap Please wait Measuring OF amp Please 12 ALL TEST PRO 33 IND User Manual Rev 2013 05H After the DF and Capacitance test is complete then the display will show the measured values Press OK to continue or MENU to remeasure to continue MENU to remeasure 2 INSULATION RESISTANCE TEST MQ Next step is the selection of Insulation Test Select NO or YES and press OK If YES is selected will be displayed indicating an empty start value for MQ Select the desired test voltage by pressing the F2 key which will toggle between the two available selections 500V or 1000V NOTE See Item 8 page 38 for guidelines to proper test voltage To perform an Insulation resistance test Press TEST key until the MO value becomes stable or gt 50 is displayed and then OK to continue LN WARNING Risk of electric shock Pressing the TEST key will output the selected test voltage of 500V or 1000V on the yellow output port and illuminate orange status LED Inzulation Test c ng HO 3 SOO2. User Manual ALL TEST PRO 33 INDUSTRIAL For Firmware IND130516A4 amp IND130516B4 or higher 2011 2013 ALL TEST Pro LLC All Rights Reserved Rev 2013 05H ALL TEST PRO 33 IND User Manual Rev 2013 05H CONTACT INFORMATION ALL TEST Pro LLC P O Box 1139 121 Spencer Plain Rd Old Saybrook CT 06475 USA Tel 1 860 399 4222 Fax 1 860 399 3180 Email support alltestpro com Web www alltestpro com Symbols used on the instrument Important information see user manual WARNING risk of electric shock Equipment complies with EU regulations and directives regarding safety and electromagnetic compatibility Do not dispose of this product as unsorted municipal waste Lead free equipment complies with EU RoHS directive regarding restriction of hazardous substances NOTE Color illustrations and images are used in this manual and we recommend printing it using a color printer if a hardcopy is desired ALL TEST PRO 33 IND User Manual Rev 2013 05H CONTENTS CONTACT INFORIVIA TION 1 INTRODUCTION mre E 3 SAFETY WARNINGS sscicsssavcnsinssscccscsnssnagaasssnannssaasssassavenseeedavanousoasnasdevissansvegeassseasenasansen s 4 INSTRUMENT WARNINGS HI EP RES 4 ALL TEST PRO 33 KIT eee M
3. General Principle An AC induction motor is a Symmetric Alternating Current Machine and when a fault occurs it creates Asymmetry in the AT33 measured data All common types of faults in the Rotor and in the Stator windings breaks the symmetry of the machine motor therefore asymmetry in measuring data indicates winding and or rotor fault For phase to phase testing the AT33 outputs a low voltage DC signal and then a sinusoidal signal at frequencies of 50 100 200 400 amp 800Hz The instrument has four connection leads of which three are used to connect to the leads of a three phase motor and the voltage clips are custom designed Kelvin clips for improved measurement accuracy The fourth lead is used for connection to the motor ground or frame Testing Sequence There are two basic testing modes Static and Dynamic At the end of either test Static or Dynamic the user is able to view the results on the instrument s display store the results in the instruments memory or upload to a computer for data storage trending and reporting It is the Dynamic test that provides the OK Warn or Bad results for the Stator and Rotor The Static test provides the OK Warn or Bad for Resistance Contamination and Insulation to ground Static Test Overview Static testing starts after the instrument leads have been connected to Phase 2 and Ground or frame An optional Dissipation Factor DF test can be done along with a capacitance to ground
4. Ht 13 ALL TEST PRO 33 IND User Manual Rev 2013 05H 3 RESISTANCE AND TEST VALUE STATIC TEST R TVS Connect the remaining Test Leads according to instructions in the message screen to prepare the instrument for the remaining STATIC amp DYNAMIC tests remaining Phase i1 to Phase 8 comntinus The AT33 will now start the fully automatic STATIC tests starting between phases 3 2 displaying STATIC Test 32 Please wait with progression bar and continuing with subsequent testing between phases 2 1 and 1 3 Includes measuring a number of parameters between the three phases such as Resistance R Inductance L Impedance Z Current Frequency Response I F and Phase Angle x together with other proprietary parameters to finally calculate TVS the Test Value Static ASTATIC Test 13 Connection 32 Check OK to skip MENU to EXIT NOTE If No Connection is detected by the AT33 you will see the warning message listed above If your connection to the motor is correct then you can force it to sequence to the next phase by pressing OK 14 ALL TEST PRO 33 IND User Manual Rev 2013 05H DYNAMIC TEST The next step provides the option to select a Dynamic Test Select NO or YES and press OK If NO is selected then the instrument will skip the Dynamic Test and go directly to the Result Menu Screen Selecting YES will start the Dynami
5. verify stable results are achieved If erratic results are seen then consult Addendum A for guidelines 3 Subsequent Insulation Static testing can be done whether for trouble shooting or other purposes If a change in either the Insulation or Static test is observed then both tests should be performed at the motor with incoming leads removed from the motor 4 This new Insulation Static test at the motor terminals should now be compared to the initial reference static test that is mentioned in item 1 a If the values have not changed from the initial static test then likely the problem is related to cables connections between starter drive and motor b If values have changed from initial static test then the user will need to perform a complete DF C Insulation Static Dynamic to determine the root cause for this change STATIC TESTS 1 CONTAMINATION TEST DF and CAPACITANCE The Dissipation Factor test DF amp Capacitance test of the AT33 is a low voltage method to measure the Dissipation Factor also known as tan delta loss angle and the Capacitive system inside the motor formed by the motor frame and the stator windings Due to the inherently high impedance nature of the DF amp C test the AT33 connection is designed to form a shielded test setup together with the motor object under test All DF amp Capacitance testing should be performed directly on the motor terminals as instructed and pictured in this Manua
6. Signature Pattern if Dynamic test was done If only STATIC test was done the Rotor and Stator fields will display use REF and subsequent sub menu will show the TVS Test Value Static number Use arrow UP amp DOWN keys to select item then press OK to enter sub menu and view details Press OK or MENU to return when done x Stator Contamination OF Insulation Mok SAME EEF Ex xIT Upload TEST WReldew IRSE 2 The Resistance Submenu will display actual R values and deviation deviation is calculated by comparing each phase to the average of the three phases The Stator Submenu will display the Test Signature Pattern if DYNAMIC test was done If only STATIC tests were done then the TVS Test Value Static dimensionless will be displayed Rotor has identical submenus as for Stator above The center solid line is the Stator signature and represents the deviation of the mean values during rotation for each phase The two black doted lines represent the Rotor Signature and include an upper and lower signature 17 ALL TEST PRO 33 IND User Manual Rev 2013 05H The image below is generated using the optional computer software not the same motor as above _ Test Signature P eee Each Phase 32 21 13 eee re Rca Cna t _ 0 oe et 9 9 SSS aster Signature Lower 4 1 3 8 4 0 96 ee Change in Impedance dur
7. TEST Pro LLC Any misuse of the Marks or any Content except as provided in this Statement is strictly prohibited and may violate trademark laws Other brands or product names used in this manual are trademarks and or service marks of their respective owners should be treated as such and may be registered in various jurisdictions 1 ALL TEST PRO is a Registered Trademark of ALL TEST Pro LLC 2 EMCAT PRO ALL TEST PRO ALL TEST IV PRO TREND AT33IND AT33EV are all Trademarks of ALL TEST Pro LLC Disclaimer Documents published by ALL TEST Pro LLC are provided as is without warranty of any kind either expressed implied or statutory including but not limited to any warranties of merchantability fitness for a particular purpose or non infringement ALL TEST Pro LLC shall not under any circumstances be liable to any person for any special incidental indirect or consequential damages including without limitation damages resulting from use of or reliance on the information presented loss of profits or revenues or costs of replacement goods even if informed in advance of the possibility of such damages Reasonable efforts have been made to ensure the accuracy of the information presented However ALL TEST Pro LLC assumes no responsibility for the accuracy of the information Product information is subject to change without notice ALL TEST Pro LLC may make improvements and or changes in the products and or
8. at any rotor position TVS is compared to TVS o A change gt 3 indicates a change in the condition of the motor or connections cables if testing from the stator or motor drive Note Warning alarm of 3 is based on a well 31 ALL TEST PRO 33 IND User Manual Rev 2013 05H manufactured motor Poorly made motors or of unusual design may require a higher limit The actual deviation of TVS2 compared to TVS1 is displayed in the instruments Compare to REF function for custom alarm limit applications Static Alarms lt 3 OK 23 lt 5 WARN NR No Reading CONTAMINATION Displayed Result 5 INSULATION Displayed Result DF BAD 220 OK ex 310X WANN gt WARN lt 15 No Reading No Reading NOR Dynamic Test Overview All three phases of the motor are connected to the AT33 and Dynamic testing requires that the user manually rotate the shaft of the motor while the instrument goes through the testing process The shaft is turned in a slow and steady manner without stopping or reversing the rotation As with the Static test the AT33 will test all phases while the shaft is moving and current inductance impedance phase angle current frequency response and other measurements are made It is the Dynamic test that provides the OK Warn or Bad results for the Stator and Rotor Moreover it provides the valuable Stator amp Rotor
9. at www alltestpro com for further information WARRANTY One year limited warranty See ALL TEST Pro Terms and Conditions for details ALL TEST PRO 33 IND User Manual Rev 2013 05H INSTRUMENT CONNECTIONS LAYOUT 0 0 amp 1 Phase 1 Test Lead input output port BLACK 2 Phase 2 Test Lead input output port BLUE 3 Phase 3 Test Lead input output port RED 4 500V amp 1000V Dissipation Factor Capacitance output test port LN WARNING Risk of electric shock 5 USB port type B for PC communication 6 Charger input DC 9V 1 7A center pin solari CAUTION Only use the supplied charger for charging Using the wrong charger could damage your instrument and void the warranty Keep instrument plugged into charger when not in use 6 ALL TEST PRO 33 IND User Manual Rev 2013 05H FRONT PANEL LAYOUT A 1 ALL TEST PRO 33 1 Graphical LCD display 128x64 white LED backlight 2 Charging status indicator LED bicolor Red Green 3 Active status indicator LED ORANGE 4 Keypad area sealed tactile switches ALL TEST PRO 33 IND User Manual Rev 2013 05H BATTERIES AND CHARGING The built in rechargeable Lithium Li ION batteries support eight hours or more of normal testing 2 5 hours is typically necessary to fully charge the battery Do not charge when ambient temperature is below or above range as listed in the specification document Charge the battery if the Te
10. measurement Then the user can perform an optional insulation to ground test Next the user will connect the remaining two leads and then the instrument will complete the Static test Static means the test is performed without moving the rotor 30 ALL TEST PRO 33 IND User Manual Rev 2013 05H The testing process is automatic and requires no user interaction once it has been initiated As part of this process the instrument will test all three phases Resistance and then current inductance impedance phase angle current frequency response and other measurements are made for all phases When complete the user is asked if they want to perform the Dynamic test if not then the Static test results can be viewed stored or uploaded to optional computer software The Dissipation Factor DF is the ratio between the resistive power loss and the reactive power loss of the insulation material This is used to detect contaminated or overheated windings The insulation to ground test measures resistance of insulation between conductor and ground Resistance is measured phase to phase and primary purpose is to detect connection problems The Static test provides a number we call Test Value Static or TVS and this can be used as either a reference value or can be compared to a previously stored TVS for comparison purposes Static General Principle For a Symmetric Alternating Current Machine motor the rotor position influences the in
11. soeed for 2 pole motor 100 RPM Maximum recommended rotor shaft rotational speed for 4 pole motor 50 RPM Maximum recommended rotor shaft rotational speed for 6 pole motor 33 RPM Maximum recommended rotor shaft rotational speed for 8 pole motor 25 RPM Maximum recommended rotor shaft rotational speed for 10 pole motor 20 RPM Maximum recommended rotor shaft rotational speed for 12 pole motor 17 RPM VIEWING THE TEST RESULTS After the STATIC and DYNAMIC tests are done the instrument will automatically analyze calculate and display the Result Menu screen reporting OK WARN BAD or NoR No Reading NOTE Additional information regarding analysis of the results is located in the Addendum 3 5 OK 23 lt 5 WARN NoReadng 8 lt 14 OK 21 1 lt 3 J WARN Only STATIC test done use REF TVS Concentric Windings CC See Addendum lt 10 OK 21096 1596 WARN Small Signature Variation 2 Note Rotor analyze is proprietary patented method 16 ALL TEST PRO 33 IND User Manual Rev 2013 05H s6 OKs zoma CONTAMINATION DF Displayed Result INSULATION MO Displayed Result gt 6 lt 1096 O gt 15 20M lt 1 5 No Reading NoR NoReading NOR The Result Menu screen has selectable submenus to display test result details including Rotor and Stator graphical Test
12. the AT33 will automatically ANALYZE the test result of each parameter and presents the result in a user friendly format Analysis results include one of three possible levels OK WARN or BAD based on the preset rules In case only STATIC testing was possible the user has the option to compare the new results with already preloaded or saved record in the memory or to save the current test as a baseline reference test Saved test records can be uploaded to the optional PC software for further analysis trending data base management and report generation ALL TEST PRO 33 IND User Manual Rev 2013 05H STATIC tests and measuring functions Test Value Static Reference Value Static patented Makes measurements on all three phases and calculates a Test Value Static which when compared to a baseline Reference Value Static becomes a powerful combined fault indicator for Rotor and Stator faults The Reference Value Static is normally saved from the first time the motor is tested a baseline test or can be saved from a known good motor when you have many of the exact same motor type Contamination Measures the Dissipation Factor DF and the capacitance between motor frame stator windings Resistance 0 9990 resolution 0 01mQ True 4 wire Kelvin measurement for accurate low resistance results includes automatic compensation for thermoelectric offset voltages Insulation Resistance 0 999MO 100
13. the motor shaft If little or no movement occurs then it is possible it will not sequence to the next phase during the dynamic test You can force the 33 to sequence to the next phase by pressing OK This does not mean that the motor is necessarily bad but instead may relate to the design construction of the motor We suggest another motor of exact same type be tested to see if the response is the same If the second motor tests normal then likely the first motor is in 36 4 5 6 7 ALL TEST PRO 33 IND User Manual Rev 2013 05H suspect condition If it tests just like the first motor then contact us for other testing options Email your technical support questions to support alltestpro com How long to turn the shaft for each phase will vary by motor but typically should not exceed 30 seconds per phase If it does take more than 30 seconds then press OK to sequence to the next phase If the next phase tests like the previous one then see item 2 above Connecting the AT33 Kelvin clips to small connection points a When making a connection to a point that is much smaller than the jaw face we recommend that only a portion of the jaw make contact i Connecting using just the front portion of the jaws as seen here Non repeatable test results should be considered to be suspect There may be external sources causing non repeatable results Contact support alltestpro com for more information Never condemn
14. x 8 6 x 2 W x Lx H basic enclosure size without minor protrusions Material Polycarbonate UL94 V2 Weight 0 7 kg 1 55 Ib Accessories included 3x Test Leads with custom Kelvin Clips and push pull connectors 1x Test Lead with 4mm safety plug and MC Dolphin clip Charging adapter Universal input type 85 260VAC output 9VDC 1 7A Attach type hard case with pre cut foam liner User Manual on CD 28 ALL TEST PRO 33 IND User Manual Rev 2013 05H Accessories NOT included Windows XP 7 based software for further analysis reporting trending and database storage 1x USB cable 1m Soft carrying pouch for instrument and test leads Specifications subject to change without notice 29 ALL TEST PRO 33 IND User Manual Rev 2013 05H ADDENDUM A TESTING GUIDE The AT33IND detects winding contamination stator faults such as turn to turn and coil to coil open connections ground faults and broken fractured rotor bars It is optimized to test AC induction motors with squirrel cage rotors that operate up to 1000VAC if your testing application includes motor operating voltages that exceed 1000V contact us at info alltestpro com for testing options It does this via Static and Dynamic testing processes that only take a few minutes and the instrument will display the following information sulation xIT Upload TEST I cr pul r 132 f R 1 E
15. 0V 0 500MO 500V Static tests except for DF and Capacitance can be performed directly at the motor or from the starter or motor drive However testing from the starter or motor drive can introduce external sources of interference that can influence the test results User should repeat any test from the starter drive to verify measurements are repeatable DYNAMIC tests and measuring functions Test Signature patented Measures in real time during manual rotation a number of parameters in all three phases which together forms the Test Signature for the rotor and stator The Test Signature is then automatically analyzed in the AT33 and gives the user immediate results for Stator and Rotor status The Test Signature can also be uploaded to the optional PC software and evaluated further by a trained technician Dynamic tests are best performed directly at the motor Testing from the starter or motor drive can introduce external sources of interference that can adversely influence the test results 10 ALL TEST PRO 33 IND User Manual Rev 2013 05H RECOMMENDED TESTING PROCEDURES 1 Prior to installing the motor a DF C Insulation Static Dynamic test should be performed directly at the motor leads and then saved as a reference test 2 After the motor is installed then an Insulation Static test should be performed from the starter drive and then saved as another reference test This test should be repeated to
16. 5 INSTRUMENT CONNECTIONS LAYOUT Leere eere ee eere nette nett ten ttn sette tons 6 FRONEPANELTAYOD T VIPMN SIS REN 7 BATTERIES AND CHARGING UR I UU VA 8 BASIC INSTRUMENT OPERATION 8 9 AC MOTOR TESTING 9 Pesce 11 1 CONTAMINATION TEST DF and CAPACITANCE 11 2 INSULATION RESISTANCE TEST eere eese eene eerte 13 3 RESISTANCE AND TEST VALUE STATIC TEST TVS 14 DYNAMIC TEST e 15 VIEWING THE TEST RESULTS sssccacesstsvassiensavensevenanssenvessss NOS QU MESE 16 SAVING TO MEMORY RAE NE 19 COMPARE TO REP c M 22 VIEWING DELETING SAVED TESTS 23 SET DATE 24 PC COIVIVIGINIGAIIOIN ue a 25 INSTRUMENT FIRMWARE VERSION 26
17. Each installed motor now has two Reference Value Static tests When needed you can perform a new test to be compared to Reference tests previously stored Useful whether trouble shooting a motor system that has quit running is running poorly or for PAM purposes 1 Perform the new Static test from the output of the starter motor drive 2 If the new TVS has changed gt 3 from the Reference Value Static this indicates a change in condition of the motor system l e connections cables or the motor itself 3 In order to determine where the change has occurred you need to test at the motor with leads removed Then compare this new test to the Reference test previously stored stored test with the power leads removed This will provide information regarding if the change in condition is connection cable related or motor related Misc 1 Instrument will power off after approximately five minutes of inactivity 2 If one motor phase is open the AT33 will state no connection and will ask you if you want to OK to skip to the next phase in order to complete the test If the connection between the motor and AT33 is correct then you can press OK and it will sequence to the next phase if on last phase then it will complete the Static test 3 When performing a Dynamic test it is important to watch the AT33 display screen while turning the motor shaft The bar will move horizontally across the screen while you Turn Rotor 32 are rotating
18. PC Communication and press OK with USB cable connected to PC the instrument will respond Ready waiting NOTE See AT33 Software Manual for additional instructions Record Ready waiting Communication SET Date Time Manual Test R L w Wer IND12 0801H4 The instrument will show one of the following message screens depending on the PC action Bbloading to PLoS Downloading Recards 15 iaumloadina rasing Memory ze walt tEecaordz l5 25 ALL TEST PRO 33 IND User Manual Rev 2013 05H Erasing Memory Please wait DONE HRecords 0 A Note The Done key in the PC software must be used to release the instrument and return to main Menu SPECIAL MODE Manual Test Reserved INSTRUMENT FIRMWARE VERSION Firmware version number is listed after the word Ver Note in the image below the firmware version is IND120801A4 26 ALL TEST PRO 33 IND User Manual Rev 2013 05H SPECIFICATIONS Test Frequencies 50 100 200 400 800 Hz Test Value Static Reference Value Static 0 01 10000 1 Dimensionless calculated value Stator Test Dynamic Repeatability 1 of measured data and calculated deviations Rotor Test Dynamic Repeatability 2 of measured data and calculated deviations Resistance 0 01 999 1 Max Resolution 0 01 Relative Accuracy Phase to Phase 0 196 True 4 wi
19. SPECIFICATIONS oe 27 ADDENDUM A AT33 TESTING GUIDE ene teen enne nnn nnn 30 DISCLAIMER COPYRIGHT amp TRADE MARKS 39 ALL TEST PRO 33 IND User Manual Rev 2013 05H INTRODUCTION to the ALL TEST PRO 33 Test Instrument Analyzer Data Collector for Electrical Motors Congratulations on your purchase of the new patented ALL TEST PRO 33 Motor Circuit Analyzer AT33 from ALL TEST Pro LLC ATP The ATP AT33 is the first in a new series of hand held Motor Test Instruments and is available in the Industrial IND or in the Electric Vehicle EV version The IND version is optimized to test AC induction motors with squirrel cage rotors that operate up to 1000VAC if your testing application includes motor operating voltages that exceed 1000V contact us at info alltestpro com for testing options The EV version is for testing Permanent Magnet PM type motors and motor generators used in hybrid and electric vehicles Additionally the EV version has application with testing other types of PM motors Contact info alltestpro com for further information The 33 series forms the base in a complete system solution for stand alone trouble shooting fault localization quality control of stored or incoming new repaired motors as well as data collection and trending for early fault detection when combined wit
20. Signatures At the end of Dynamic test results can be viewed stored or uploaded to optional computer software Dynamic General Principle An AC induction motor is a Symmetric Alternating Current Machine and when a fault occurs it creates Asymmetry in the AT33 measured data All common types of faults in the Rotor and in the Stator windings breaks the symmetry of the machine motor therefore asymmetry in measuring data indicates winding and or rotor fault While the shaft is turned measurements and calculations are made in real time and without an external motor shaft position sensor From these measurements and calculations two important Signatures are presented at the end of the test Stator and Rotor 32 ALL TEST PRO 33 IND User Manual Rev 2013 05H Instrument Display Phases 3 Rotor Upper Signature 3 Stator Signature 3 Rotor Lower Signature 3 Change in impedance during rotation Below is how it appears using the computer software not the same motor as above _ Test Signature _ 32 21 13 en ee re ee 9 aa e ee 99 TOUS ec ee 4 1 3 8 4 0 TITO ca e Change in Impedance during rotation Rotor Signature Lower Dynamic Signature Analysis The Green line is the Stator signature and represents the deviation of the mean values during rotation for each phase Note that for Phase 1 3 the Stator signature is sligh
21. User Manual Rev 2013 05H Insulation Submenu will display Insulation resistance in MQ or gt 50 or if NoR Insulation SAVING to MEMORY The instrument can store a maximum total of 819 records in the internal memory as TEST or REF record or any mix of the two The only difference between the two record types is how they have been tagged by the user prior to saving SAVE as a TEST record or SAVE AS REF as a Reference record SAVE REF selection will display Submenu for saving and comparing to REF functions Selecting QUICK SAVE allows the user to SAVE test by just entering alphanumeric characters into the Motor ID Ser field Use arrow keys and OK key to select and enter the alphanumeric characters available on rows 1 2 and 3 Cancel will take you back to the Results screen PREV is not functional in this particular mode 19 ALL TEST PRO 33 IND User Manual Rev 2013 05H SAVE and SAVE as REF allows the user to SAVE a test or SAVE as REF that includes additional data such as Company Motor Type HP etc Selecting either will display the Input Motor Data parameters screen starting with Company Use arrow keys and OK key to select and enter the alphanumeric characters available on rows 1 2 and 3 Important Note All Motor Data information is optional input but we strongly recommend to fill in at least one of the following three key moto
22. a motor from the Motor Control Center Faults in the cabling or connections between the test point and the motor itself can cause a fault indication Before condemning a motor always perform a confirming test at the motor with the motor leads disconnected from the supply cabling Dissipation Factor and Capacitance testing Erratic readings b Ifa beep is heard during the C amp DF test this indicates a problem with the measurement Test should be repeated if beep is heard again then something is interfering with testing process Connection external interference etc c Any leads not used for the C DF test that are connected to the motor phase terminals can act as antennas and couple interference to the sensitive high impedance node Solution Only use the Blue and Yellow test leads connected to motor terminals during C and DF test d The motor test set up could be in closer than normal proximity to a single interference source like fluorescent light frequency inverter cell phone etc Solution Disconnect power temporarily to suspected interference source if possible Move test object or EMI source Test again at a later time to see if EMI is lower 2 37 ALL TEST PRO 33 IND User Manual Rev 2013 05H e The general interference levels of the site at large could surpass the limits for Heavy Industrial Environment according to CE testing Solution Disconnect power temporarily to suspected interference source s if possible Move t
23. c test il Dynamic Test HO Start by turning the Rotor as slowly and smoothly as possible by using the bar graph as a visual feedback aid Continue turning rotating the rotor while the AT33 automatically switches to the next phase to phase connection displayed in the following order Turn Rotor 7 NOTE If No Connection is detected the instrument you T 2 Turn Rotor zl will see the warning message listed above If your connection m o to the motor is correct then you can force it to sequence to the next phase by pressing OK NOTE When performing a Dynamic test it is important to watch the AT33 display screen while turning the motor shaft Turn Rotor 13 The bar will move horizontally across the screen while you are mem 5 O rotating the motor shaft If little or no movement occurs then it is possible it will not sequence to the next phase during the dynamic test You can force the 33 to sequence to the next phase by pressing OK This does not mean that the motor is necessarily bad but instead may relate to the design construction of the motor See MISC item 3 page 36 for more information 15 ALL TEST PRO 33 IND User Manual Rev 2013 05H Rotation Speed Guidelines Start by turning the Rotor slowly and as smoothly as possible by using the bar graph as a visual feedback aid Maximum recommended rotor shaft rotational
24. creen is displayed when the test record has been saved successfully Press OK to return to Result screen Resistance 2atator Rotor Contamination Insulation SAWE REF ESIT Upload TEST return 21 ALL TEST PRO 33 IND User Manual Rev 2013 05H COMPARE to REF Select SAVE REF in the Result screen and COMPARE to REF in the submenu and press OK to enter this function and display available Find REF search function Select function and press OK Select func tion NN Find REF BUICK SANE uc SAWE aue Browse saved REF SANE az LoOmpare CANCEL CANCEL Instrument will search through saved REF records and display three key parameters Location Motor ID Ser and Motor Type of the first REF record found Press OK to find browse NEXT REF record or select USE to compare displayed REF to the current test ID Sers Motor HEST Ha CHHCEL USE CANCEL The AT33 will display the result of the comparison as a deviation of the current Test Value Static to the saved REF Test Value Static TVS In addition it will also display one of these findings OK WARN or BAD according to preset limits lt 3 OK 23 lt 5 WARN TUuZdeuz2 22 to return 22 ALL TEST PRO 33 IND User Manual Rev 2013 05H EXIT Upload TEST Submenu to select EXIT or Upload current TEST without saving To send a si
25. ductances L impedances Z or Phase Angles Fi of each stator differently since the rotor position influences the coupling of the L Z and Fi between stator windings and rotor winding However due to the Symmetry of the motor the measured calculated Test Value Static TVS of the stator windings is independent of the rotor position Note In practice TVS may be slightly influenced by the rotor position due to inaccuracies during assembly of the motor or motor parts manufacturing tolerances slight differences between stator windings flaws in the rotor measurement inaccuracies etc See Figure 1 All common types of faults in the Rotor and in the Stator windings breaks the symmetry of the motor As a result the TVS will change and no longer be independent of the rotor position Consequently a second TVS will no longer be equal to the first TVS TVS z TVS Static Testing Sequence The AT33 outputs a low voltage sinusoidal signal at frequencies of 50 100 200 400 amp 800Hz and then does the following e Calculates Test Value Static TVS in the first rotor position o Rotor position has little influence on TVS value in a good motor e TVS is a motor specific parameter o be used as a Reference REF value for detecting fault conditions o used as a REF value for that specific motor or other motors of exact same amp manufacturer A subsequent test the AT33 calculates a new TVS
26. est object Test again at a later time to see if EMI is lower 8 Insulation to Ground Recommended Test Voltage amp Minimum Insulation Test Values from IEEE 43 NOTE The following tables provide the recommended voltages and Minimum Insulation Resistance to ground values If these values differ from your equipment manufacture follow their guidelines The motor should be above dew point temperature before testing if possible It is important to correct values to a reference temperature typically 40 C so that trends and changes in insulation resistance can be readily detected Contamination humidity temperature and other factors affect insulation resistance values APPLICATION PASS FAIL VALUES Windings prior to 1970 1 Meg ohm 1Meg ohm perk rating of motor Random Wound motors 1000 V gt Meg Ohm Motor Voltage InsulationResistance Test Voltage 1000 Volts AC 38 ALL TEST PRO 33 IND User Manual Rev 2013 05H Disclaimer Copyright amp Trademarks Notice of Service Trademark Rights The trademarks service marks and logos collectively the Marks set forth below are registered and unregistered trademarks and or service marks owned by ALL TEST Pro LLC in the United States and certain other countries throughout the world Nothing contained in this manual should be construed as granting by implication estoppels or otherwise any license or right to use any of the Marks without the written permission of ALL
27. h the optional PC software The ALL TEST PRO 33 performs Motor Circuit Analysis MCA as a series of low voltage tests to identify faults inside an electric motor The AT33 detects winding contamination stator faults such as turn to turn and coil to coil open connections ground faults and broken fractured rotor bars Experience has proven that the ALL TEST PRO series of Motor Test Instruments are the most powerful and easiest to use diagnostic tools available for de energized testing of motors in today s industry The AT33 is designed to be used as a stand alone unit in the field or workshop or with optional Windows based software for further analysis reporting trending and database Has a built in real time clock and large memory for storage of test and reference data The instruments are built to exacting standards and rugged to handle the daily use in tough industrial environments The rechargeable Lithium batteries support eight hours or more of testing and data collection Assumes most testing is phase to phase Performing insulation to ground testing in applications where there are long cable runs will increase the drain on the battery Therefore user may not get 8 hours of use between battery charges ALL TEST PRO 33 IND User Manual Rev 2013 05H SAFETY WARNINGS Safety Warnings and Precautions must be read and understood before the instrument is used They must be observed during use Follow all safety rules of you
28. ing rotation Dynamic Signature Analysis The Green line is the Stator signature and represents the deviation of the mean values during rotation for each phase Note that for Phase 1 3 the Stator signature is slightly elevated above the other two phases This indicates the mean values for Phase 1 3 are slightly higher than the other two phases but are within acceptable limits and this stator is in good condition The two black doted lines represent the Rotor Signature and include an upper and lower signature This represents the deviation of the peak values during rotation As the output of the instrument is sinusoidal and the response of the motor will be sinusoidal there will be peak values both positive and negative There are 8 dots for each phase and if this were an 8 pole motor then this represents 1 full revolution of the motor shaft If this were a 2 pole motor then it represents 4 revolutions of the motor shaft If this were a 12 pole motor then it represents 34 of a revolution of the motor shaft With this Rotor signature there is a slight variation in the distribution of the peak values but as they are within our limit this rotor is in good condition The change in impedance represents the change in impedance during rotation of the shaft Contamination Submenu will display DF in and Capacitance in nF If C is less than 1 it will display 1 to continues to remeasure 18 ALL TEST PRO 33 IND
29. l Only the supplied shielded test leads and clips should be used The use of any additional cable s between the test clips and motor terminals can introduce hum and or other interference that can result in erratic readings for DF and C In addition longer cable lengths can also add the influence of the cable itself In order to get the highest possible accuracy for the DF test the instrument should be allowed to have a warm up time of approximately 10 seconds after powering ON this allows time for the DC and offset levels to stabilize Note that the specification for DF and Capacitance is based 11 ALL TEST PRO 33 IND User Manual Rev 2013 05H on battery powered operation The USB communication cable cannot be connected to a computer during the Contamination test described below To start motor testing Select the IND icon in Main Menu and press OK key Now connect the Test Leads according to instructions in the message screen Connect BLUE clip to Phase 2 and YELLOW to Frame OK to continue This connection will prepare the instrument for the DF Capacitance and Insulation tests Connect BLUE clip to Fhase 2 and YELLOW to OK to continue A message screen during the DF and Capacitance measurements will appear displaying DF amp Cap Test Press NO to skip or YES to Continue NOTE DF amp Capacitance test is optional BOF 4 Cap Test with firmware version numbers
30. ngle test record to PC software via the USB connection select Upload TEST and press OK The right hand orange Status LED will be ON during the short data transmission time Exit lif YES Upload TEST VIEWING DELETING SAVED TESTS Functions are available by selecting the SET icon in the main menu Menu choices include VIEW Test Records DELETE last Record and CANCEL 23 ALL TEST PRO 33 IND User Manual Rev 2013 05H VIEW Test Records allows you to view any record in memory DELETE Last Record is the only delete function the instrument offers NOTE The computer software will allow you to download all test results from instrument memory View them Save them and upload back into the instrument See the software manual for details SET DATE TIME The date and time can be set from the SET Menu Select SET Data Time and then press the OK key 24 ALL TEST PRO 33 IND User Manual Rev 2013 05H Use arrow k ews OK when done Using the left right arrow keys move the cursor to the date or time to be changed The up down arrow keys will change the displayed value Press OK when done to exit to the main menu PC COMMUNICATION The optional Windows based AT33 PC software must be installed and the instrument must be set into PC Communication mode before any Uploading or Downloading of saved test records to PC can take place Select
31. nly the motor manufacturer can provide this information A stacked winding concentric wound may cause asymmetry depending upon construction therefore the reason for the analysis algorithm With this type of motor construction a Stator Warning may instead be caused by winding construction instead of a winding fault The Warning level for a Stator fault is set at 21 196 and when a CC warning is shown and the Stator is in a Warning condition then care should be taken before condemning the motor Steps to confirm include 1 Test a known good motor of exact same model and see if the CC warning and alarm appears a If CC and Warning appears then motor is likely good 2 Contact motor manufacturer to determine winding construction 24 ALL TEST PRO 33 IND User Manual Rev 2013 05H Figure 1 Test Object 4 4 lest Value Static TVS 360 Rotor position RECOMMENDED TESTING PROCEDURE New Motor 5 Prior to installing the motor a DF C Insulation Static Dynamic test should be performed directly at the motor leads and then saved as a reference test 6 After the motor is installed then an Insulation Static test should be performed from the starter drive and then saved as another reference test This test should be repeated to verify stable results are achieved If erratic results are seen then consult Addendum A for guidelines 7 Subsequent Insulation Static testing can be done
32. ow keys and then press OK key How to RESET the instrument Simultaneously press the left and right arrow keys for a few seconds and then release This will perform a forced hardware amp firmware reset and will return the display back to the main menu ALL TEST PRO 33 IND User Manual Rev 2013 05H MAIN MENU OH IHS SET 2011 02 17 14 25 54 The MAIN MENU presents the user with the following main selection icons and information e IND icon selects Testing Industrial AC Motors using all available instrument features e DYN icon selects Dynamic only motor testing e INS icon selects Insulation Resistance only testing e SET icon selects various set and support functions e PWR OFF icon selects power off e Battery voltage status indicator shows one of four levels or LOW e Real Time Clock Date and Time information AC MOTOR TESTING STATIC amp DYNAMIC The new Patented amp Patent Pending analysis methods and measuring technologies are divided into two main testing types STATIC and DYNAMIC The term STATIC refers to the testing methods possible when the rotor shaft is not accessible for rotation l e rotor shaft position is fixed The term DYNAMIC refers to all testing methods possible when the rotor shaft is accessible for manual rotation whether by hand or other aid during testing After completing a test path
33. r company and OSHA or country equivalent for off line testing methods including the wearing of appropriate Personal Protective Equipment PPE Improper or unsafe operation of the ALL TEST PRO 33 is the sole responsibility of the user The ALL TEST PRO 33 is only to be used on de energized motors Connecting the instrument to live voltage will destroy the unit and void the warranty Always verify the motor circuit is de energized before connecting the AT33 Ensure that all power has been removed from the circuit being tested including static power stored in capacitors Discharge all capacitors being tested During testing ensure that one leg of any power factor correction capacitor or lightning arrestor that is in the test circuit are disconnected to avoid erroneous test results For MCA testing the ALL TEST PRO 33 sends out a low voltage high frequency test signal not harmful to the technician or most electronic equipment variable frequency drives and soft starters However electronic equipment and personnel must observe appropriate safety considerations disconnect electronic equipment when performing the insulation to Ground Resistance Test Meg Ohm test Test leads including crocodile clips must be in good order clean and have no broken or cracked insulation AN INSTRUMENT WARNINGS Do not open the main body of the instrument Electrostatic charges may damage surface mount electronics Additional battery packs can be purcha
34. r data Location Motor ID Ser and Motor Type NOTE Date amp Time of test is included with the test data from instruments internal clock Move cursor with arrow keys to highlight the NEXT Motor Data command when done with Company and press OK for the next Motor Data Location IECDEFGHI JKLHNHOPGE HECDEFIGHI 4 STUH YZE ERASE An0 HS FREN NEXT CANCEL CHHCEL Compan Lome ATF oe 12 Enter Motor Location as desired ABCOEFGHI JELNNOPOR STUUM AY 201234 5E7 8 ERASE r Ado Locat ion POR FS 20 ALL TEST PRO 33 IND User Manual Rev 2013 05H Proceed likewise with the next two parameters Motor ID Ser and Motor Type HE End 1OPGE HELCLEFGHI STLLb PME STU REY E FASE ERASE PRE ll ELS FREU Waksi CHHCEL Motor 102 Motor Remaining optional Motor Data in this screen are Manufacturer Motor Size kW Motor Size HP Motor Speed RPM Current A Voltage V CosFi and Insulation Class When CONTINUE appears press OK for next and last two steps AEC feo JELMNAOPGR STUUWAY 20125345678 ERASE Rae FEEL CHHCEL LON TINUE F Select the last two fixed selection parameters Connection and Condition and press OK et Connection ma IT odd RM IT fee fu fu C ITI Copa rpm MH uu The following s
35. re Kelvin measurement Compensation for thermoelectric offset voltages Dissipation factor DF frame stator 1 10096 measurement range expressed as a percentage 1 1096 0 5 C 10 1000 nF 10 30 1 0 This specification is based on battery operation and USB not connected to PC Capacitance frame stator 2 2000 nF measurement range 10 1000 nF 5 This specification is based on battery operation and USB not connected to PC Insulation Resistance 0 999 1000V 0 500 500V 1 100 MQ 3 all other values 5 Connections 3 x Motor input output push pull connectors 4 pole High Voltage output 4mm safety jack PC communication USB type B connector Charger input 2 5mm diameter center pin DC jack Keyboard Sealed tactile touch XL size keys 27s ALL TEST PRO 33 IND User Manual Rev 2013 05H Display Graphic LCD monochrome 128 x 64 pixels 3 1 white LED backlight Temperature range storage 20 C to 60 C 4 F to 140 F Temperature range operating 10 C to 50 C 14 F to 122 F Humidity 0 80 relative humidity non condensing Safety According to IEC 61010 1 cat II 1000V Approvals CE EMC EN61000 6 4 Emission EN61000 6 2 Susceptibility Calibration Certificate Optional contact nearest distributor for more information Batteries 2 Li ION cells with gt 2100 mAH capacity Enclosure Size 126 x 218 x 51 mm 5
36. sed from ALL TEST Pro but care must be exercised during battery installation as electrostatic charges may damage surface mount electronics Contact your distributor of the AT33 or ALL TEST Pro 1 860 399 4222 or email info alltestpro com to purchase a battery pack and for battery installation instructions NOTE Only approved original equipment OEM battery pack should used and use of non OEM types will void your warranty ALL TEST PRO 33 IND User Manual Rev 2013 05H Use only the supplied charger for charging the instrument It is an integral part of the charging circuit Using the wrong charger could damage your instrument and void the warranty ALL TEST PRO 33 KIT STANDARD EQUIPMENT e ALL TEST PRO 33 with back lit graphic LCD screen 128x64 pixel e 3x Test leads with custom Kelvin Clips 1x Test lead with 4mm safety plug and Dolphin clip e Battery charging adapter e Attach type hard case with pre cut foam liner e User Manual on CD AVAILABLE ACCESSORIES e Windows XP 7 based software for database storage further analysis reporting and trending e USB cable 1m for PC communication e Soft carrying pouch for instrument and test leads e Battery pack and DC charger TRAINING Continuing Education Accredited Training Courses are held at various locations throughout the world In addition all of the ALL TEST Pro training courses can be customized and brought to your plant site Contact ALL TEST Pro training department
37. ster is not used for extended periods CAUTION Only use the supplied charger for charging Using the wrong charger can damage your instrument Charging status is indicated by bicolor LED to the left of keyboard Red Battery conditioning and charging Green Charge complete Done Red Green Sleep mode or temperature fault OFF Charger not connected Battery voltage is independently monitored and indicated in the main menu as one of four possible levels or will show the word LOW When the charger is plugged into line power the charging circuit automatically resumes charging when the battery voltage falls below the preset threshold Note The Li ION batteries have built in over discharge protection circuits activated if the cell voltage falls below a threshold that will disconnect the cell resulting in no power The solution is to recharge the batteries BASIC INSTRUMENT OPERATION Turning the instrument ON Press the ON key for a few seconds until the display lights up and shows the main menu Instrument will power off after approximately five minutes of inactivity Note If the instrument does not turn on the most likely cause would be that the Li ION batteries built in over discharge protection circuits have switched off resulting in no power The solution is to connect the charger to the instrument in order to recharge the batteries Turning the instrument OFF Select the PWR OFF icon in the main menu with the arr
38. the programs described in these publications at any time without notice Information in this document is 2011 2013 ALL TEST Pro LLC All rights reserved You may cite or refer to information published in this manual except as provided below but you may not reproduce or distribute such information in whole or in part without the prior written permission of ALL TEST Pro LLC You may not reproduce or distribute any image from the Manual without securing advance written consent from ALL TEST Pro LLC To request such permission send email to info alltestpro com including your name address and a description of the purpose of your intended distribution and the information you would like to distribute 39 ALL TEST PRO 33 IND User Manual Rev 2013 05H You may print reproduce and use the information in and retrieve files containing software or images from ALL TEST Pro LLC for non commercial personal or educational purposes only provided that you i do not modify such information and ii include any copyright originally included with such information and this notice in all such copies Nothing contained herein shall be construed as conferring by implication or otherwise any license or right under any patent or trademark of ALL TEST Pro LLC or any third party No other rights under any copyrights of ALL TEST Pro LLC or any other party are granted herein except as expressly stated above 40
39. tly elevated above the other two phases This indicates the mean values for Phase 1 2 are slightly higher than the other two phases but are within acceptable limits and this stator is in good condition The two black doted lines represent the Rotor Signature and include an upper and lower signature This represents the deviation of the peak values during rotation As the output of the instrument is sinusoidal and the response of the motor will be sinusoidal there will be peak values both positive and negative There are 8 dots for each phase and if this were an 8 pole motor then this represents 1 full revolution of the motor shaft If this were a 2 pole motor then it represents 4 revolutions of the motor 33 ALL TEST PRO 33 IND User Manual Rev 2013 05H shaft With this Rotor signature there is a slight variation in the distribution of the peak values but as they are within our limit this rotor is in good condition The change in impedance represents the change in impedance during rotation of the shaft for each phase Dynamic Alarms 21196 lt 3 WARN OKO 210 lt 15 WARN Small Signature Variation lt 2 With lt 2 variation Concentric Windings A CC warning is an indicator that the difference in the Stator Signature may be related to winding construction The instrument cannot determine with 100 certainty the type of winding used in the motors construction O
40. whether for trouble shooting or other purposes If a change in either the Insulation or Static test is observed then both tests should be performed at the motor with incoming leads removed from the motor 8 This new Insulation Static test at the motor terminals should now be compared to the initial reference static test that is mentioned in item 1 a Ifthe values have not changed from the initial static test then likely the problem is related to cables connections between starter drive and motor b If values have changed from initial static test then the user will need to perform a complete DF C Insulation Static Dynamic to determine the root cause for this change 35 ALL TEST PRO 33 IND User Manual Rev 2013 05H RECOMMENDED TESTING PROCEDURE Installed Motor If the motor is performing well then you make an assumption it is in good condition Here is a suggested testing process to establish a baseline test for comparison purposes 1 Perform a Static test only no Dynamic test at the output of the starter motor drive and save the Test Value Static TVS as a Reference test Reference Value Static Note skip the DF Capacitance test but do perform the insulation to ground test 2 Next go to the motor remove incoming power leads and perform the Static only test again no Dynamic test This TVS will be stored as another Reference Value Static test Note perform both the DF Capacitance and insulation to ground tests 3
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