2024 ALL-TESTPro IntroductiontoMotorDiagnosticsFinal

Introduction to
Motor Diagnostics
2024
WHO WE ARE
ALL-TEST Pro, LLC
We are a world leader in de-
energized & energized test
instruments, used for
predictive maintenance and
trouble shooting/quality
control of electric motors,
generators, alternators, coils
and windings.
• Parent company
established in 1983
• Privately held
• Provide worldwide sales
and service
© 2023 ALL-TEST Pro, LLC 2

ATP MARKETS SERVED
(ALL PRODUCTS)
• Petro-chemical • Pharmaceutical
• Automotive manufacturing • HVAC
• Mining • Water treatment & wastewater
• Basic metals (steel, aluminum, treatment
copper, etc.) • Power generation
• Pulp/paper manufacturing • Building maintenance
• Wood products • Food processing
• Cement manufacturing • Aerospace
• High technology manufacturing • Drilling (oil & gas)
• Bottling plants • General manufacturing
• Refining • Logistics
• Marine industry
© 2021 ALL-TEST Pro, LLC
SOME OF OUR BEST
KNOWN CUSTOMERS
ABB Caterpillar Gerdau Ameristeel Pfizer
Abitibi Bowater Chrysler Hershey Pratt & Whitney
Alcoa Cirque Du Soleil Holcim Qatar Petroleum
Aluminerie Alouette Conoco Phillips Husky Energy San Antonio Water
Anheuser-Busch Delta Electric IBM Saudi Aramco Mobil Refinery
ArcelorMittal Dofasco Steel International Paper Shell
Arch Coal Domtar Kimberly Clark Siemens
Atomic Energy Canada DuPont Lafarge Southern CA Edison
BASF Electric Boat Lyondell Space Coast Launch
Bayer Ensco Manitoba Hydro Sunoco
Boehringer Ingelheim Equistar Miller Coors Suwannee American Cement
Boeing Evergreen Energy Morton Salt Syncrude
Bosch Exxon Mobil Chemical NASA ThyssenKrupp
BP FedEx Nestle Texas Instruments
Bristol Aerospace Ford New Brunswick Power Tinker Air Force Base
Brunei Liquefied Natural Gas GE Sensing & Inspection Nucor Total
Burullus Gas Company Genentech Panama Canal TransAlta
Canadian Advanced General Mills Pasadena Refining Systems UPS
Canadian Natural Resources General Motors PEMEX US Coast Guard
Cargill Georgia Pacific Petromont US Steel
Weyerhaeuser
MOTOR RELIABILITY QUESTIONS
• Have you ever installed a new motor and had it fail on start up or run a
short time and then fail?
• Have you ever found a motor in your spares inventory and its electrical
condition was unknown?
• Have you ever received a repaired motor and it didn’t run? Or didn’t run
the same way as before?
• Do you sometimes solve a motor system problem by just replacing parts?

MOTOR RELIABILITY QUESTIONS
• Do you ever get a “no problem found” report from your motor shop?
• Have you ever had trouble determining if the motor drive, motor,
connection, cable or load was the cause of a motor system not running at
all or running poorly?

WHAT IS A MOTOR SYSTEM
The Electric Motor System

Three-Phase Process Mechanical and Electrical Feedback
Input Power
Motor/Drive Subsystem Mechanical Subsystem
1200 rpm

MOTOR SYSTEM FAULTS
The next series of slides illustrate some

common faults found within a motor system
1200 rpm

INCOMING POWER &
TRANSFORMERS
Power Quality
• Harmonics (Voltage and Current)
• Over/Under Voltage
• Voltage Unbalance
• Power Factor
• Overload
Transformer Faults
• Insulation to Ground
• Winding Shorts
• Loose Connections
• Electrical Vibration

MOTOR CONTROL
CENTER & CABLES
MCC/Disconnect Problems
• Loose Connections
• Bad Contacts & Coils
• Bad PF Correction Capacitors
Cable Faults
• Thermal Breakdown
• Contamination (especially underground feeders)
• Shorts and Grounds
• Open - Physical Damage

MOTOR MECHANICAL
& ELECTRICAL
Mechanical Faults
• Bearings/Bad Shaft/Brg Housing
• Vibration
Electrical Faults
• Winding Shorts
• Insulation to Ground
• Contamination
• Thermal Stress
• Rotor Faults
• Air Gap Faults

COUPLING (DIRECT AND
BELTED) & LOAD
Faults
• Misalignment
• Belt/Insert Wear
• Tension Issues
• Sheave Wear
Load Faults
• Worn parts (I.e. seals)
• Broken components (gears, fan, impeller blades,
etc.)
• Bearings, etc.

WHY YOU SHOULD HAVE A MOTOR
TESTING PROGRAM

INDUSTRY AVERAGE DOWNTIME
COSTS/HOUR
Industry Avg Cost Per Hour*
Forest Products $7,000
Food Processing $30,000
Petro-Chemical $87,000
Metal Casting $100,000
Automotive $200,000
*Numbers originate from United States Department of Energy Best Practices Program (2010)
Costs must include lost production

and labor utilization

14
DOWNTIME COSTS
What are the downtime costs at your facility?
Costs must include lost production and labor utilization
Do not overlook the costs associated with an environmental hazard

due to an unexpected equipment failure

EQUIPMENT FAILURE PATTERNS*
*Reliability-Centered Maintenance, December 1978, Nolan & Heap. Also known as the United Airlines study.
This study and others have demonstrated that failure for most complex systems is
not age related. The purpose for showing this slide is to demonstrate the value of
commissioning your motor system prior to starting up production. Moreover, as
new motors and repaired motors will occasionally exhibit infant mortality, testing
before installation and after installation will help reduce your start up failures.
IMPROVE MOTOR SYSTEM
RELIABILITY
Deenergized Testing Energized Testing

Using: Using:
Motor Circuit AnalysisTM (MCA™️) Electrical Signature Analysis

(ESA)

IMPACT OF USING DEENERGIZED
TESTING FOR MOTOR COMMISSIONING
Some new motors are delivered with defects

• Estimated average downtime $10,000/hr.
• 3 hours average uncoupling/coupling
• Average savings $30,000 with a single find
Can recoup investment with a single “find”
Also applies to repaired and spare motors
Do you know the status of your spares?

DEENERGIZED TESTING FOR
COMMISSIONING
Three primary areas for commissioning:
1. Sometimes new motors or repaired motors fail on start up and the cost
associated with removing and replacing a “new” motor that has failed can
cost justify adding an off-line motor testing program at your facility.
Motors to be tested may include:
• Any that impact life safety (such as confined space entry required to
access motor)
• Any that impact the environment
• Critical to production
• High labor cost associated with replacement

COMMISSIONING
2. In many plants, the person that decides what motor vendor to use is not
the person that is responsible for keeping them running.
Use de-energized motor testing to determine not only the condition of the
motor, but the quality of the motor:
• Example: a cheap, poorly made motor may run well in some
applications, but in a critical area you may want to install a motor that
is more electrically balanced (impedance balance).
• With a meg-ohm meter and digital multi-meter you do not know the
quality of the motor you are installing.

COMMISSIONING
3. Lastly, test the motor before you send out for repair and then upon its
return to confirm it was repaired correctly and you have the same motor
when it comes back.
• i.e.- same wire size and winding design was used with repair, as some
motor shops will change based on their internal repair procedures.
Many times, this will not impact the performance of the motor, but
sometimes it can. Again, you cannot see this type of issue with a meg-
ohm meter or digital multi-meter.

ENERGIZED TESTING FOR MOTOR
SYSTEM COMMISSIONING
ESA evaluates the entire motor system while it is running
Evaluate incoming power, the motor mechanically and electrically, and the
driven load
• Verify your contractor did the work properly
• Helps eliminate infant mortality
• Baseline the motor system for predictive maintenance purposes

COMMISSIONING
WRAP UP
In some facilities, commissioning alone can easily
cost justify starting a deenergized and energized
motor testing program.
Payback on the initial investment can

usually be measured in just a few months!
Driving results, from the shop floor to the

top floor

$ IMPACT OF USING DEENERGIZED
TESTING FOR TROUBLESHOOTING
Hours saved in Finds “good” Eliminates wasted

identifying the motors as well as time in R&R
problem “bad” motors
Looks at connections, Eliminates “no problem 3 hours X $/hour = ???
cable and motor from found” at the motor
MCC, at starter, at shop
VFD, or at disconnect.
Takes the guesswork
out of determining if
you have a mechanical
or electrical problem.

$ IMPACT OF USING ENERGIZED
TESTING FOR TROUBLESHOOTING
Detects many electrical and mechanical issues*
• Incoming power analysis including harmonics

• Motor electrical & mechanical (stator, rotor, air gap, bearings,
alignment, and more)
• Couplings, power transmission, driven load
* Details about fault finding using ESA

will be discussed later in this presentation

ENERGY IMPACT OF
IMPEDANCE UNBALANCE
50HP Motor with 3.5% Impedance Unbalance
• 50 hp * .746 * 0.85 * [(100/91) – (100/95)] = 1.47 kW

• $14/kW * 1.47 kW/mo. * 12 mo./yr = $246.96/yr
• $0.06/kWh * 6,000hrs/yr * 1.47kW = $529.20/yr
% Increase In Motor Losses
80
70
60
50
40
30
20
10
0
0 1 2 3 4 5 6 7 8
Impedance Unbalance
Increased Annual Energy Costs = $776.16

ENERGIZED TESTING FOR
MOTOR EFFICIENCY
• ATPOL IIITM ESA calculates motor efficiency for AC induction & DC motors
• Can be used to data log motor system energy use and report in either
kWh or actual dollars
App. Power Real Power Reac. Power

Power factor Impedance kVA kW kVARS
Phase 1 0.891 6.169 19.821 17.658 9.003
Phase 2 0.866 6.021 20.316 17.596 10.155
Phase 3 0.891 6.171 19.885 17.716 9.031
Avg/Total 0.883 6.120 60.022 52.970 28.189
% dev 1.9 1.6
Demand Pwr = 71.01 HP [Load: 86.8%, Motor Eff.: 91.8%, Output Pow.: 48.6 kW, Output Trq.: 192.0 Ft.Lb]

COST JUSTIFICATION WRAP UP
INCOMING INSPECTION TROUBLESHOOTING
Prevent start up failure Get system running

(motor & motor system) quickly
EITHER WILL EASILY COST JUSTIFY A MOTOR TESTING PROGRAM
Plus – we have not included using for:

Predictive maintenance practices!
Driving results, from the shop floor to the

top floor
WHAT DOES
“FIELD TESTING”
REALLY MEAN?
Accessing installed motors:
• In a confined space
• On top of a roof
• At a dryer or oven
• In a pit (submersible)
• May require climbing a stairway or ladder
• Any outside location

WE ARE HERE TO
IMPROVE MOTOR SYSTEM
RELIABILITY BY:
• Testing new motor inventory to verify condition
before installing into service
• Testing existing motors for immediate health
• Trending test data for predictive maintenance
practices
• Electrical signature analysis testing for complete
system health

MOST MOTOR FAILURES HAVE A
GESTATION PERIOD
The condition develops over a period of time.
• Once the condition is advanced, it is usually easy to tell.
• If you have the right tools and knowledge, you can detect the condition in its early
stages.
o i.e.- Before the “blue smoke” is released!

A
Coil to coil
MOTOR
ELECTRICAL
Turn to turn FAULTS
Many faults start at the end turns of
the windings
B • Greatest stresses
• Insulation is weakest
Phase to phase
They start small and get worse
They always end in failure
MΩ Coil to Ground
Contributing factors:
C • Overloading
• Frequent start/stop cycling
• Vibration
• Contamination
• Age, heat, VF drives

A
Coil to coil
STATOR
Turn to turn
FAULTS
If the only motor test you perform
is with a Meg-Ohm or High
B Potential Tester you will miss
these stator faults
Phase to phase • Turn to Turn
• Coil to Coil
MΩ Coil to Ground
• Phase to Phase

MOTOR SYSTEM – TYPICAL TESTING
PROGRAM
PQ Cntrl Conn Cable Stator Rotor Air Gap Ins Brgs Vibe Align Load VFD
Off-Line (De-energized) Testing
High Potential- - - - - - - - - - - - -
DC
Meg-ohm Meter - - - - - - - - - - - -
Ohm Meter* - - - - - - - - - - -
PI Testing - - - - - - - - - - - -
On-Line (Energized) Testing
Vibration - - - - - -
Infrared - - - - -
Volt/Amp - - - - - - - -
Combined Approach
GAPS -
Green indicates that a developing fault can be both detected and trended for Predictive Maintenance purposes.
Yellow indicates a fault can be detected but is difficult to trend or cannot be detected at its very earliest stage.
*Using a low-cost digital multi-meter- typical tool used by an electrician

UNFORTUNATELY, MOTORS DON’T HAVE
A CUT-AWAY VIEW
You need another option!

DEENERGIZED MCA️TM
CAPABILITIES
• AC/DC motors
• Generators/Alternators
• Machine tool motors
• Servo motors
• AC/DC traction motors
• Control transformers
• Transmission & distribution transformers
(Virtually any size)*

* Specific to the AT7TM Series

MEGOHMMETER & VOLT/OHM-METER
When used for electrical motor testing*
Internal Open
Ground Faults Rotor Faults Contamination
Winding Faults Connection
Meg-ohm Meter YES NO NO NO YES
DMM NO NO YES NO NO
Motor Circuit
Analysis TM YES YES YES YES YES
(MCATM)*
*Using the AT34TM and AT7TM

I can see inside this motor…
Can you?
MCA️FAULT
DETECTION
• Turn faults • Connection resistance
• Coil faults • Rotor eccentricity
• Phase faults • Broken rotor bars
• Ground faults • Casting voids
• Cable faults
Any motor size

Any voltage motor controller

MOTOR CIRCUIT ANALYSISTM (MCA️)
BASIC CONCEPT
• MCA️is a low voltage, sine wave test method that measures/calculates up
to 7 electrical parameters* and then optionally perform dissipation factor
and insulation to ground tests
• Non-destructive and safe for personnel performing this deenergized test
*Number of parameters depends upon MCA️instrument

MOTOR CIRCUIT ANALYSIS (MCA️)
BASIC CONCEPT
These 7 measurement parameters are:
1. Resistance
2. Impedance
3. Inductance
4. Fi (phase angle)*
5. I/F (current frequency response)*
6. Test Value StaticTM (TVS™️)*
7. Dynamic Stator and Rotor SignaturesTM*
* Details will be provided later in this

presentation

MOTOR CIRCUIT ANALYSIS (MCA️)
BASIC CONCEPT
In a healthy 3-phase motor, all winding measurements
should be balanced
ALL BALANCED ONE OR MORE UNBALANCED
GOOD NOT GOOD
LOOK AT AND COMPARE MULTIPLE MEASUREMENT PARAMETERS

TO DETERMINE THE REASON
It is that simple!

WHERE TO
TEST
• Motor control center or
disconnect
o Will detect all faults
between test point and
motor winding
o If fault found, go to
equipment
• At winding connections
• Not only detects faults, but
will identify what is NOT
faulty

MCA WRAP UP

PROGRAM
Off-Line (Deenergized) Testing
High Pot - - - - - - - - - - - -
Meg-ohm Meter - - - - - - - - - - - -
Ohm Meter - - - - - - - - - - -
PI Testing - - - - - - - - - - - -
Infrared - - - - -
Volt/Amp - - - - - - - -
Combined Approach
GAPS -

MOTOR SYSTEM – ADD MCA TM

High Pot
- - - - - - - - - - - -
Meg-ohm Meter - - - - - - - - - - - -
Ohm Meter
- - - - - - - - - - -
PI Testing
- - - - - - - - - - - -
MCA  Test
- - - - - -
Vibration
- - - - - -
Infrared
- - - - -
Volt/Amp
- - - - - - - -
Combined Approach
With MCA
-

WHAT IS A MOTOR SYSTEM?
The Electric Motor System
Three-Phase
Input Power Process Mechanical and Electrical Feedback
Motor/Drive Subsystem Mechanical Subsystem
1200 rpm

MOTOR SYSTEM FAULTS HAVE
UNIQUE FAULT FREQUENCIES
Type of Fault Pattern (CF)
CF = RS x Stator Slots
Stator Mechanical
LF Sidebands
CF = RS x Rotor Bars
Rotor Indicator
LF Sidebands
Static Eccentricity
LF and 2LF Sidebands
Mechanical Unbalance Proprietary algorithm is used
Dynamic Eccentricity
LF and 2LF Sidebands with Running Speed Sidebands
Stator Electrical (Shorts) Proprietary algorithm is used

ENERGIZED TESTING WITH
ELECTRICAL SIGNATURE ANALYSIS
ALL-TEST PRO On-Line III™️

• ESA
• Power quality
• Sags & swell
• Waveform capture
• Energy data logging
• Supports multiple languages
*Currently supports Spanish, Chinese,

French, & English languages
ESA BRIEFLY DESCRIBED
• High frequency capture of current and voltage waveforms
• FFT analysis of captured signals
• Detects many electrical and mechanical issues
o Incoming power quality including harmonics
o Motor electrical & mechanical (stator, rotor, air gap, bearings, alignment
and more)
o Couplings, power transmission, driven load
A motor is a great transducer!

ESA BRIEFLY DESCRIBED
60 Hz
60 Hz
120 Hz
120 Hz
180 Hz
180 Hz
60 + 120 + 180 Hz
60 120 180
SUCCESSFUL
APPLICATIONS
OF ESA
• AC/DC motors
• VFD applications
• Generators/Alternators
• Traction motors
• Machine tool motors
• Gearboxes
• Pumps and fans
• Reliability testing
• Commissioning
• Troubleshooting

ESA STANDARD REPORTS
& ALARMS*
• AC induction
• AC induction on motor drive
• DC motor
• Synchronous motor
• Generator
• Asynchronous generator
• Transformer
* Not all software packages are the same.

Some vendors’ basic software will not include
analysis of AC motor drive’s, DC motors, etc.
AC MOTOR ANALYSIS REPORT
All alarms are pre-set
Power Quality & Current Machine

• Power factor • Load to nameplate
• Current & voltage unbalance • THDF (transformer harmonic
• RMS voltage to nameplate de-rating factor)
• Voltage and current peak and • VDF (voltage de-rating factor)

crest factor • Product of THDF & VDF can be
• Phase impedance used for de-rating horsepower
• Power (apparent, real and

reactive)
• Total harmonic distortion
(voltage and current)

Machine Machine
• Demand power • Air Gap (static & dynamic
• Efficiency for AC induction & DC Eccentricity)
motors • Misalignment/Unbalance
• Voltage & current high
frequency spectrum (FFT)
• DeMod spectrum
• Winding shorts
• Stator mechanical
• Harmonics (V & I)

Machine Other
• Mechanical system can be fully • Waveform
analyzed after information is o Phase A voltage and
entered into the software current waveforms
o Gear box
• Harmonic distortion
o Belted o Total negative, positive and
o Fan blade zero sequence harmonics
o Impellor are shown
• Impedance unbalance
• Phase connection health

POWER ANALYSIS
Power Quality Data Logging
3 channels of voltage and 4 channels of current logging

• 125KHz sample rate
o Waveform capture of events ≥ ½ cycle
o Transient detection of events ≥ 8 micro-seconds
o Energy data logging
o Harmonic analysis to 65th (V & I)
o Phasor graphs
o Pre-set and easy to use report templates
o Report energy savings using a before and after analysis function

POWER ANALYSIS
Power monitoring with the ATPOL IIITM will provide answers
to these types of questions:
We need to document energy savings

• How are the energy savings measures we have implemented performing?
We need to reduce energy consumption
• I need to perform an energy audit to evaluate energy savings opportunities.
We need to trouble-shoot incoming power
• This transformer is very hot – is it overloaded or are high harmonics the
cause?

POWER ANALYSIS WITH ENERGY
SAVINGS REPORT
Before vs. after comparison report (abridged)

ALL-TEST PRO On-Line III™ Software
ATPOL IIITM can be

remotely operated by
using the Bluetooth
interface and a laptop
computer
No need for the user to
stand in front of an
energized electrical panel
while collecting data

ALL-TEST PRO
On-Line III™ Software
• Data is uploaded from data

collector via wireless
Bluetooth interface
• Or from provided SD
memory card
• Enter nameplate data

ALL-TEST PRO
• Motor type
• Nameplate
o HP or kW
o RPM
o Voltage
o Current

ALL-TEST PRO
• Number of phases that you

are connected to
• C+V or C only
• Mechanical system

ALL-TEST PRO
• Rotor bar & stator slot

counts
o -1 if unknown
• CT and PT ratio
• Efficiency for AC induction
& DC motors
• Enter driven load
information
• Can save a motor type as
a default

ALL-TEST PRO
• Enter bearing information

• If unknown, enter: -1 in
bearing multiplier field
• Can save as default

ALL-TEST PRO
• Enter plant information

• Enter other information as
needed
• Can save as default

ALL-TEST PRO
• Enter motor information

• Can save motor type as
default

DATA
ANALYSIS
• Critical points are
automatically detected
• Analysis is automated
• Short summary report is
generated for a quick view
of motor system condition

DATA
ANALYSIS
• Motor efficiency is
calculated for AC induction
and DC motors (uses
NEMA MG-1 table)

AUTOMATED SUMMARY REPORT

AUTOMATED SUMMARY REPORT

PAGE 3 DATA SUMMARY
Motor Voltage
Rotor Health
Bearing

ESA- LOW FREQUENCY TEST DATA
(120HZ)
Pole pass frequency sidebands around line frequency- early

indication of cracked or broken rotor bars.

COMPARE TO PREVIOUS TEST
Low frequency spectrum:

• Black = no load
• Blue = 75% load
• Blue shows a rotor fault

MULTIPLE INDICATIONS,
ELECTRICAL AND MECHANICAL

DATA
TRENDING
• Database search
o Compare graph
 Quickly identify
changes in machine
performance
 Same motor or
between different
motors
 Calculates mean &
standard deviation

ALL-TEST PRO On-Line III™
• Handheld data collector
• 8-current probes
o 4 @ 1 – 6000A flex probes
o 4 @ 0.1 – 100A
• Route testing
• 4 voltage leads
• Bluetooth wireless communications*
• Memory card slot for additional memory storage (memory card included)
• Companion PC software
o For analysis, reporting, and trending
* The Bluetooth® word mark and logos are owned by Bluetooth SIG, Inc.


ALL-SAFE PRO
ALL-SAFE PRO comes complete with 3- current transformers


ALL-SAFE PRO
Current
ALL-SAFE PRO  Transformers
Voltage
Connections

ALL-SAFE PRO

ALL-TEST PRO On-Line III™
Advantages
• ESA, not just MCSA
• Hand-held data collector with wireless control
• Automated analysis and reporting for AC induction, DC, & synchronous
motors. Plus, generators and transformers
• Route testing
• Automated alarms
• No extra cost for DC motor or motor drive analysis- included with
equipment purchase.
• Great tech and application support

ALL-TEST PRO WILL IMPROVE
MOTOR SYSTEM RELIABILITY BY
• Testing new motor inventory to verify condition before installing
into service
• Testing existing motors for immediate condition
• Trending test data for predictive, preventative maintenance
• Electrical signature analysis testing for complete system health

TRAINING
• Deenergized testing & energized testing training courses
• Following IACET continuing education credit standards
• Earn ATP continuing education unit credits (CEU)
• Society for Maintenance and Reliability Professionals (SMRP) approved
supplier
Solutions and support for the life of your product.

The same expertise that goes into the configuration and delivery of
every ALL-TEST Pro instrument is available through comprehensive
training for the life of the customer relationship.

IMPLEMENTING ESA
Motor nameplate information is required
• Good to get this information ahead of time
Motor system information is needed to confirm faults related to driven load
• Ask for basic equipment information as part of your initial survey. I.e.,
belted, geared, direct drive, bladed, etc.

IMPLEMENTING ESA
There will be occasions where exact stator slot or rotor bar information will
be required
Additional data collection will sometimes be required as part of the analysis
phase
• May include using your other instruments

ESA DATA ANALYSIS EXAMPLES
The following series of slides provide some examples of various faults
detected using ESA

POWER ANALYSIS: EFFICIENCY
Media Studio- survey of entire building including chillers, pumps, air
handling fans, etc.
Unit HP RPM Volts Amps Frame KW KVA kVARS PF HP Eff Load % Manuf.
10S8 7.5 1787 208 23.2 213T 2.08 2.79 1.8 0.747 2.8 57.7 55.6 Baldor
10S9 5 1796 207 15.8 184T 5.16 5.79 2.61 0.907 6.93 89.5 81.7 GE
10R30 3 1791 210 6.7 182T 1.29 2.39 2.01 0.484 1.73 68.6 49.9 GE
10R22 7.5 1758 221 9.9 213T 2.71 3.78 2.82 0.708 3.65 87.1 63.1 GE
10S29 10 1716 211 18.2 215T 1.95 6.44 6.48 0.791 2.61 55.1 45.1 GE

POWER ANALYSIS: EFFICIENCY
147 Motors surveyed:
o Majority are 1.5HP to 40HP fans
o 9- 150-200HP Pumps
o 5- 900-1000HP Chillers
o Of the 147 motors:
o 40 motors loaded < 60%
o 17 motors loaded < 50%
Average efficiency for the 40 motors with

loads under 60% is 78%

INCOMING POWER: VOLTAGE
• 300HP, 440V pump

• Voltage to motor exceeds
nameplate by +11%

The following conditions are likely to occur with an over-voltage situation as
shown in the prior slide
o Efficiency will decrease
o PF will decrease
o Starting & breakdown torque will increase
o Starting current and temperature rise will increase

250HP, 440V motor
Over voltage & load < 50%
Low power factor = Wasted energy

STATOR MECHANICAL ANALYSIS
1200 Ton Chiller (1) of (2)
o Service company technician detected possible stator mechanical
problem
o This chiller is a back up and the application is critical
Deenergized MCA™️test showed

windings to be in good condition

STATOR MECHANICAL ANALYSIS
As this was a critical application vendor of the chiller was contacted to verify stator
slot count. There are no peaks in alarm behind software generated cursors, which
indicate stator mechanical condition is good.
Stator slots- 48 x 59.601Hz = 2860.84 Hz +-60Hz SB
Type of Fault Pattern (CF)

CF = RS x Stator Slots
Stator Mechanical
LF Sidebands

ESA MECHANICAL
ANALYSIS
Discussion of how ESA can be
used for mechanical system
analysis

COMMON
MECHANICAL
FAULTS LOAD
(Fans, Pumps, Compressors,
Gearboxes, Etc.)
• Load Faults
o Worn parts (I.e. seals)
o Broken components
(gears, fan, impeller
blades, etc.)
o Bearings, etc.

MECHANICAL ANALYSIS
Not that long ago, you had to do

the mechanical frequency analysis
by hand.

ESA SOFTWARE AUTOMATES THE
CALCULATIONS AND PROVIDES
FREQUENCY CURSORS
Enter Information about

the Mechanical system:
• Pump • Direct Drive
• Fan • Bearing
• Gear
• Belted

DUST COLLECTOR FAN 1
Current Log Spectra- Demod (dB) Belt Frequency (BLT) & Multiples of BLT
BLT- 4.3A @ 7.2Hz

Motor Current- 220A
Current Spectra Belt Frequency Sidebands around Line Frequency
Line
Freq.

DUST COLLECTOR FAN 2
Current Log Spectra- Demod (dB) Belt Frequency (BLT) & Multiples of BLT
BLT- 8.3A@ 7.2Hz

Motor Current- 194A
Dust Collector Frequency Peak: Fan2 Belt is 8.3A vs. 4.3A for Fan 1
• Load difference is ~ 26A yet Belt Frequency Peak is almost 50% higher
o Lower load but higher belt peak
• Technician made quick visual inspection of the belt for both machines
o Fan 2 belt showed excessive belt movement when compared to Fan 1
Next step would be to do some additional

work as part of the Analysis Phase of the
PdM process.
BELT SIGNATURE OVER TIME
Belt Frequency peak is ~0.022A @ 82.6% Load

Machine is monitored over the course of 1 year
This first test was done in February of 2010

Belt Frequency after 2nd test- 0.16A @ 76% Load

Tested in May of 2010
Belt Frequency after 3rd test- ~0.6A @ 77% Load

February of 2011

Belt Frequency after change- ~0.09A @ 69% Load

BEFORE BELT
CHANGE

AFTER BELT
CHANGE

BELT
SIGNATURE
OVER TIME
Old Belt

MOTOR BEARING FAULT 1
Chiller 200HP, 480V on motor drive
Motor put back into service after bearing replacement

Routine ESA test performed about 2 weeks later
ESA tests detects “Possible Bearing Fault”

CHILLER CONT’D
Energized test report lists: “Possible Bearing Fault”
o Software makes this call when it detects peaks in current that are not
integer multiples of running speed (not a whole number).
Technician verifies Line Frequency, Running Speed, & PPF are correct
Bearing multiplier is 23.449

CHILLER CONT’D
Center frequency = 23.449 x running speed = 698.42

Line frequency sidebands = +-60 hz
Green & red marks show power harmonics

On-line test report lists: “Possible Bearing Fault”
o Software makes this call when it detects peaks in current that are not
integer multiples of running speed (not a whole number)
Technician verifies line frequency, running speed, & PPF are correct
Bearing multiplier is 35.884

Center frequency- 35.884 x running speed = 715.56

Line frequency sidebands = +-60hz
Green & red marks show power harmonics

MOTOR
BEARING
FAULT 2
Software calls out cage fault
which is confirmed using
vibration analysis.

PROGRAM
High Pot - - - - - - - - - - - -
Meg-ohm Meter - - - - - - - - - - - -
Ohm Meter - - - - - - - - - - -
PI Testing - - - - - - - - - - - -
Infrared - - - - -
Volt/Amp - - - - - - - -
Combined Approach
GAPS -

MOTOR SYSTEM – ADD MCA TM

High Pot
- - - - - - - - - - - -
Meg-ohm Meter - - - - - - - - - - - -
Ohm Meter
- - - - - - - - - - -
PI Testing
- - - - - - - - - - - -
MCA  Test
- - - - - -
Vibration
- - - - - -
Infrared
- - - - -
Volt/Amp
- - - - - - - -
Combined Approach
With MCA
-
Yellow indicates a fault can be detected, but is difficult to trend or cannot be detected at its very earliest stage.

MOTOR SYSTEM- ADD MCATM & ESA
High Pot - - - - - - - - - - - -
Meg-ohm Meter - - - - - - - - - - - -
Ohm Meter - - - - - - - - - - -
PI Testing - - - - - - - - - - - -
MCA  Test - - - - - -
Infrared - - - - -
Volt/Amp - - - - - - - -
ESA - -
Combined Approach
Multi-Tech
Approach
Yellow indicates a fault can be detected, but is difficult to trend or cannot be detected at its very earliest stage.

ALL-TEST PRO TOOLS
Deenergized (Off-line) Motor Circuit Analysis TM (MCA™️) for
• Troubleshooting
• Incoming inspection
• PdM testing (excluding MOTOR GENIE®)
• Accurate and fast motor testing, anytime, anywhere
ALL-TEST PRO 34TM ALL-TEST PRO 7TM

MOTOR GENIE® ALL-TEST PRO 7TM
PROFESSIONAL

ALL-TEST PRO TOOLS
Energized Electrical Signature Analysis (ESA) for
Complete motor system health

• Incoming power quality & drive health
• Motor health including rotor
• Driven load mechanical health
ALL-TEST PRO On-Line IIITM

QUESTIONS?

ALL-TEST Pro, LLC
PO Box 1139 │ Old Saybrook, CT 06475
Ph: 860.399.4222 │ Fax: 860.399.3180 │ [email protected]
alltestpro.com

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Introduction to

© 2023 ALL-TEST Pro, LLC 2

© 2021 ALL-TEST Pro, LLC

© 2021 ALL-TEST Pro, LLC

The Electric Motor System

Motor/Drive Subsystem Mechanical Subsystem

© 2021 ALL-TEST Pro, LLC

The next series of slides illustrate some

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Industry Avg Cost Per Hour*

Forest Products $7,000

Food Processing $30,000

Metal Casting $100,000

Costs must include lost production

© 2021 ALL-TEST Pro, LLC

Costs must include lost production and labor utilization

Do not overlook the costs associated with an environmental hazard

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Deenergized Testing Energized Testing

Motor Circuit AnalysisTM (MCA™️) Electrical Signature Analysis

© 2021 ALL-TEST Pro, LLC

Some new motors are delivered with defects

Can recoup investment with a single “find”

Also applies to repaired and spare motors

Do you know the status of your spares?

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Payback on the initial investment can

Driving results, from the shop floor to the

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Hours saved in Finds “good” Eliminates wasted

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• Incoming power analysis including harmonics

* Details about fault finding using ESA

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• 50 hp * .746 * 0.85 * [(100/91) – (100/95)] = 1.47 kW

Increased Annual Energy Costs = $776.16

App. Power Real Power Reac. Power

© 2021 ALL-TEST Pro, LLC

Prevent start up failure Get system running

EITHER WILL EASILY COST JUSTIFY A MOTOR TESTING PROGRAM

Plus – we have not included using for:

Driving results, from the shop floor to the

© 2021 ALL-TEST Pro, LLC

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© 2023 ALL-TEST Pro, LLC

© 2023 ALL-TEST Pro, LLC

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© 2023 ALL-TEST Pro, LLC

(Virtually any size)*

© 2021 ALL-TEST Pro, LLC

Meg-ohm Meter YES NO NO NO YES