Our focus continues to be with field testing where people must climb stairways and ladders, or enter confined spaces to access electrical motors, generators and transformers. Trying to use bulky, heavy equipment or even line powered equipment in the field is difficult.
Small, battery operated instruments are easy to slip into a tool kit or even a large pocket and there are many places in a plant where line power is not available.
The ALL-TEST PRO 5™ has been successfully used on equipment from fractional through 10’s of thousands of horsepower. Our technology allows us to test windings regardless of physical size, power and voltage rating. Tests can be performed at the motor, motor control center or disconnect from a few to hundreds of feet distant.
ALL-TEST PRO® instruments are designed to collect basic deenergized electrical information which can be immediately reviewed by the user. With simple rules, the user can quickly evaluate the condition of the motor without having to understand the type of information or how a motor works. This information can also be entered or uploaded into ALL-TEST PRO® software programs, such as MCA PRO™, for the ALL-TEST PRO 5™, TREND™/EMCAT PRO®, for the ALL-TEST IV PRO™, ALL-TEST PRO 33 IND™ Software for the ALL-TEST PRO 33 IND™, Condition Calculator for the ALL-TEST PRO 31™, and the MOTOR GENIE® Condition Calculator® APP, for the MOTOR GENIE®, which will provide you with detailed results and allow you to trend results over time.
All of the ALL-TEST Pro instruments provide step-by-step menus for the operator along with simple data interpretation rules. The ALL-TEST Pro software for both MCA™ and ESA technologies provide automated analysis of the electric motor and related systems. With MCA™, an average skilled electrician will be able to operate and do basic data interpretation with only a few hours of self training. Taking test data with the ESA instrument and uploading to the software requires little training and the reporting for many common motor system faults is automatic. However, determination of severity of fault and faults related to mechanical problems within the motor system will require additional knowledge of the system under test and the experience of the operator.
Battery life is controlled by many factors including number of discharge/charge cycles, storage practices, temperature, etc. Therefore, battery productive life span can vary greatly. Under the conditions specified for battery testing, those batteries can be charged/discharged for several hundreds of cycles and still stay at or near its full capacities. However, in our long experience we find the batteries for these instruments last between 3-5 years. If the testing time is diminishing then we suggest replacing the main battery.
Typically there are two sets of windings on a single phase motor Start/Run. Any capacitor must be disconnected. First, measure the start winding. With the run winding engaged, take your next set of readings. These can be trended over time or compared to a known good motor of the exact same kind.
If the battery charging indicator comes on when the power supply is connected but the batteries do not charge, this could be an indication that the batteries are in need of replacement. The batteries in your ALL-TEST IV PRO can be replaced by a qualified electronics repair technician. There are six (6) AA Nickel-Metal Hydride in the unit: Four (4) in the battery compartment, and two (2) inside the instrument. The batteries should always be replaced as a set.
May indicate that the motor shaft is being turned, small voltages may be present on the motor leads due to electromagnetic induction or grounding issues, or if the winding resistances are below the instrument range. Confirm the absence of voltage using the AT31™ EMI test mode or other suitable volt meter capable of accurately measuring voltage below 1 volt. If “Bad Readings” is displayed, press OK on the ATIV™ key pad to skip to the next phase. However, note the phase to phase test results may be compromised. Contact [email protected] for more information.
Absolutely not. The ALL-TEST IV PRO™ is the only instrument of its type to present both inductance and impedance readings. Therefore, if you see a phase unbalance in inductance, you can immediately compare it to impedance. This method is used to determine if an unbalance is due to winding contamination or overheated windings. Evaluation can be done in a glance or via software. Other inductive-based instruments require a 20 – 30 minute rotor test to determine the cause of the phase unbalance and usually leave the user unclear as to the results. Rotor faults account for less than 5% of motor failures (EASA, 2001), which is down from 10% (EPRI, mid-1980’s). Normally, a rotor test is only performed during troubleshooting as it requires movement of the shaft.
Commonly, ALL-SAFE PRO connection boxes are installed at the motor controller. Standard leads on the ALL-SAFE PRO current transducers are six feet (6ft) in length, so the box can be installed anywhere within six feet of the motor circuit conductors.
It’s recommended that you press the left/right arrow keys simultaneously to perform a “reset” when an unexpected result occurs. This anomaly can occur due to external reasons such as the motor shaft is turning during the Static testing, EMI, etc.
Its recommended that you press the left/right arrow keys simultaneously to perform a “reset” when an unexpected result occurs. This anomaly can occur due to external reasons such as the motor shaft is turning during the Static testing, EMT, etc.
OOR means the measurement you have just taken is “Out of Range”. Reset the instrument by pressing the left and right arrow keys together simultaneously which will take you back to the main menu. Ensure incoming motor test leads are disconnected and only the Blue and Yellow test leads are attached between the instrument and the motor. Retest. If you see this message again, then likely the cause is the measured value is outside the measuring range of the instrument. Or it can be caused by external sources such as energized cables, retained energy in the motor, etc. Please refer to the instrument manual for details regarding measuring range and accuracy.
Its recommended that the dynamic testing be 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.
The ALL-TEST PRO 5™ is designed to test AC/DC electric motors, including synchronous and wound-rotor motors; AC/DC traction motors including locomotive and hybrid vehicle motors; Control coils and transformers; Transmission and Distribution transformers; Machine tool motors; Servo motors; and virtually any type of coil-wound device of any size, power and voltage.
This message will display if the user is not associated with a company. Every username must be unique if you have multiple “Company” entries. You must go to the “User” tab and make sure the user is associated with the company they’re assigned to.
The “Exception” error is often caused by routine JAVA updates and can be easily resolved. Navigate to C: Program Files (x86) / EMCAT PRO®. Find the file [CFRestore.exe] and double click to run. Accept and agree to everything you are offered. No data or setup information will be lost or relocated.
All test data uploaded from the AT5 instrument are placed in the import pending data table of the company that the current logged in user is associated with. Each user must be associated with a company. If you have logged in using a UserID that is associated with a company different from the one you’re working in then the data will not be visible to you. Or if you have logged in using the default UserID password combination of Admin/admin (which is not associated with any company) data will not be visible to you.
No. You are correct that some companies collect waveform data for 3-phases of V & I, but the trade off is the equipment is much larger and typically has limited battery life when compared to the ATPOL II™.
A single phase of voltage and current waveforms and the resulting FFT analysis are all that is required to do a complete evaluation of the entire Electrical Motor System as described in our literature and what is displayed in the automatically generated software report.
The ATPOL II™ does collect voltage and current measurements on all 3-phases for power calculations and analysis, but for detection of problems related to stator slots and rotor bars plus mechanical system, it uses one phase of voltage and current FFT.
A 3-phase FFT is not required for the types of electrical and mechanical problems the instrument software will evaluate for. Therefore, this allows us to use a small, handheld, battery operated data collector instead of a system built around a laptop computer.
All of our main competitors have built their instruments around a laptop computer so they are much larger, heavier, and have a more limited battery life compared to the ATPOL II™.
Additionally, they do not offer a Bluetooth wireless interface which means the user must stand in front of an energized panel while collecting the motor data. This means they are exposed to a potential Arc Flash event.
The ATPOL II™ software has a virtual instrument mode that allows for remote connection and control via the Bluetooth interface. Therefore, the user can control the ATPOL II™ from a laptop computer up to 10 meters away (depending upon local RF interference), which improves the safety of the user.
Moreover, when performing on-line motor testing the ATPOL II™ is just a data collector so there is no need to take a computer into the field when testing. The ATPOL II™’s SD memory card will hold thousands of test files so there is no need for a large computer drive for test data storage.
No. Our main competitors reduce line voltage inside their connection boxes. The ALL-SAFE PRO® connection box passes through the line voltage without any loss in signal. Anytime you reduce a signal you lose a little in the process and we believe this is a clear competitive advantage. Therefore, when connected to a 575V AC motor, the ATPOL II™ via the ALL-SAFE PRO® connection box is working with full line voltage. Of course, for systems over 1000V potential transformers are required.
Additionally, we offer as standard configuration current transformers for the ALL-SAFE PRO® with an insulation class rating of 5000V. Therefore, you can use our current transformers on motor systems up to 5000V. The typical current transformers that are used in a machine metering system have poor accuracy and frequency response, so you again lose some signal due to the poor quality current transformers. The current transformers used with the ALL-SAFE PRO® are of higher accuracy and response range when compared to common current transformers. Of course, you will still need to install potential transformers for voltages above 1000V.
We offer on a special order basis split core current transformers so they can be installed without dropping the phase leads and can have a insulation class rating to 9000V.
We take safety very seriously and the ALL-SAFE PRO® connection box has an interlock system that will not allow line voltage to be passed unless the instrument is fully connected and the instrument detects current on phase A. Therefore, when the instrument is not connected to the ALL-SAFE PRO® plant personnel are not exposed to hazardous voltages.