All Test Pro

ESA Energized Testing

 

Energized 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.

At ALL-TEST Pro, we want business owners to understand that motor failure can happen when you least expect it. Just because a motor appears to be functioning correctly does not mean that its internal components are in pristine condition. We cater to professionals in industries such as wastewater, power generation, automotive and steel production by providing preventative maintenance techniques you can trust for long-lasting investments.

The Need for Energized Equipment Testing

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.

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ALL-TEST PRO On-Line II™

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 like bearings, gearboxes, impellers, belt and pulley, static/dynamic eccentricity and more

What is ESA?

Electrical Signature Analysis (ESA) is an energized test method where voltage and current waveforms are captured while the motor system is running, to assess the health of the motor system. Energized testing provides valuable information for AC induction and DC motors, generators, wound rotor motors, synchronous motors, machine tool motors, and more.

MCA how does it work

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. With ESA you have both the current and the voltage FFT on the same screen, so it’s just a matter of comparing the voltage and current FFT spectra to determine the source of the fault.

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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.  Its 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.

ALL-TEST Pro Energized Testers

One of the advantages of working with ALL-TEST Pro for energized testing equipment is our products are both compact and user-friendly. We recommend the ALL-TEST PRO On-Line II™ for readings of AC/DC motors, generators and transformers across your facility. Know exactly how much power is running through your system and if voltage leaks are present. Lightweight designs make this hand-held device portable for reading diagnostics surrounding stators, rotors and the driven load.

Our technology goes above and beyond other energized testers on the market with unlimited memory storage (with SD card) and options for Bluetooth or USB connectivity to PC. Business owners can accompany ESA instruments with one of our energized testing accessories such as the ALL-SAFE PRO® attachment. This makes repeat testing as easy as possible with a permanently mounted connection to your system.

All you have to do is hook up your connection cable from the ALL-TEST PRO On-Line II™ device, and you can receive uninterrupted motor status reports in 60 seconds.

Applications of Electrical Signature Analysis 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

Perform Energized Testing With ALL-TEST Pro Technology

ALL-TEST Pro is dedicated to providing our customers with the diagnostic tools, software and support they need to keep their businesses up and running. Channeling over 30 years of service and experience, we’ll give you insight on the condition of your equipment to spare your workers and facility unplanned downtime. All of our energized testing equipment is available for worldwide distribution, and we invite you to fill out a contact form with us online for quotes and further information about our products.