ESA Energized Testing


Electrical Signature Analysis (ESA)

Electrical Signature Analysis (ESA), which encompasses both Motor Voltage Signature Analysis (MVSA) and Motor Current Signature Analysis (MCSA), is an energized test method where voltage and current waveforms are captured while the motor system is running. Energized testing provides valuable information for AC induction and DC motors, generators, wound rotor motors, synchronous motors, machine tool motors and more.

Mtor circuit evaluation, or MCE, being used in facility.

How Does ESA Work?

All ESA systems require motor nameplate information of voltage, running speed, full load current, and horsepower (or kW). Optional information including rotor bar and stator slot count, bearing numbers, and information for driven load components – such as blade count for a pump or tooth count for a gearbox application – can be entered for a more detailed and accurate analysis.

A Fast Fourier Transform (FFT) creates the spectral display, and the algorithms perform a spectral analysis on voltage and current waveforms to detect faults related to incoming power, the control circuit, the motor itself, or the driven load. These can then be trended for condition-based maintenance and predictive maintenance purposes.

The key difference between Motor Current Signature Analysis (MCSA) and ESA is with MCSA the FFT is done on the current waveform only, not the voltage. This makes it more difficult to easily distinguish incoming power related problems from motor and driven load problems. ESA compares both the current and the voltage FFT on the same screen, making it easy to analyze the voltage and current FFT spectra to determine the source of the fault.

The need for energized equipment testing

There are certain situations where machines and motors run 24/7/365 to keep projects on schedule. Equipment in areas such as manufacturing plants or production lines may involve electrical circuit systems that undergo intense levels of stress due to constant use. If you are in a position where you require safe diagnostics while an electric motor is still running, ALL-TEST Pro brings customers hand-held devices for identifying errors directly at the source.

Energized equipment should only be handled by trained technicians, but ALL-TEST Pro gives you the opportunity to monitor motor behaviors between inspections. With easy-to-use controls, our resources allow your crew to compare the outputs of machines for a reference point between new equipment and setups currently in use. Instead of waiting for an unforeseen system shutdown, our resources find errors, eliminate the chances of workplace injury and enable you to make an educated decision when replacing motor parts.

The need for energized equipment testing comes into play as motors deteriorate with exposure to changing temperatures, moisture, vibration and dust. Whether your equipment is installed indoors or outdoors, ALL-TEST Pro devices report imbalances from:

  • Voltages
  • Currents
  • Harmonic distortions
  • Power factors
  • Mechanical systems (bearings, gearboxes, impellers, belt and pulley, static/dynamic eccentricity, etc)
The ATPOL III is an electric motor condition monitoring device by ALL-TEST Pro that uses electrical signature analysis.

The Importance of ESA

Finding a motor fault before it breaks can save your organization countless hours of downtime and thousands of dollars in savings, justifying itself immediately.

Our ESA tester is actually two instruments in one.  It’s a complete Power Quality Analyzer (PQ) and a complete Motor Analyzer (ESA). When in PQ mode it can be used for energy data logging, harmonic analysis, voltage and current charting, viewing waveforms, waveform capture of sags and swells, transient capture, and event capture.

ALL-TEST Pro offers unmatched motor testing technology. Our instruments are portable, safe, and easy-to-use allowing you to evaluate equipment in the field, shop floor, or at a service facility. Save hours of troubleshooting and avoid catastrophic damage and costs due to motor failure.

Applications of ESA Equipment

ESA testers and equipment are effective for acquiring data that is normally dangerous to access. Instead of disassembling machines, installations make it possible to test multiple systems in a single day with safety protocols in mind.

ALL-TEST Pro energized testing equipment is suitable for the following motor builds and functions:

  • AC/DC Motors
  • VFD Applications
  • Generators
  • Traction Motors
  • Machine Tool Motors
  • Gearboxes
  • Pumps and Fans
  • Reliability Testing
  • Commissioning Testing
  • Troubleshooting
  • Energy Evaluation

The ALL-TEST Pro Promise

ALL-TEST Pro is committed to ensuring the reliability of your businesses’ motors to maximize optimal productivity of maintenance teams everywhere. Our equipment is used in commercial, government and military institutions worldwide. Applications include AC/DC electric motors, transmission, distribution transformers, machine tool motors, servo motors, AC/DC traction motors and more.

About ALL-TEST Pro

ALL-TEST Pro is a leading manufacturer of electric motor predictive maintenance (PdM) equipment and condition monitoring tools. ALL-TEST Pro electric motor testing devices surpass other instruments by accurately and quickly diagnosing motor health issues to ensure electric motor reliability and reduce unnecessary facility operational and repair costs. All diagnostic instruments are handheld and lightweight making them exceptionally suitable for field testing applications. The current line of motor testing devices use Motor Circuit Analysis (MCA), a proprietary technology developed by ALL-TEST Pro, and electrical signature analysis, to evaluate electrical issues of components within motors. ALL-TEST Pro products are widely used in nearly every industry that uses electric motors, generators or transformers, and are available worldwide.

Contact Us

Email: [email protected]
Tel: +1 860-399-4222
Fax: 860-399-3180

Email: [email protected]
Tel: +1 860-399-4222

Corporate Headquarters
20 Research Parkway, Suite G
Old Saybrook, CT 06475

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