Test on installed, de-energized E-Motors

stator Test

electric Motors Test

intermediate tests during E-Motor repair

Testing of DC armatures

Motor maintenance

During maintenance work, the e-Motor with a user-friendly "AutoTest" fully automatically. The MotorAnalyzer3 automatically switches the various test methods to the four measuring sockets one after the other via its internal relay matrix. In the case of inaccessible installation positions, a test can also be carried out directly on the control cabinet via the connection cables to the electric motor .

In case of discrepancies, manual individual tests can also be run subsequently. It is therefore perfectly suited for fault analysis.

The AutoTest includes the following tests:

• Resistance
• impedance
• inductance
• Capacitance
• insulation resistance, DAR, PI
• High Voltage
• surge test

The regular maintenance measurements are collected in the results database and are thus available for trend analysis, for example, throughout the entire service life of the electric motor.

After transfer to the PC software PrintCom, the results can be documented in a comprehensive test protocol.

Electric motor repair

For electric motor repair, the AutoTest is excellently suited for:

• Incoming test
• Intermediate tests
• Final test

After each repair step, the electric motor and/or the stator can be analyzed quickly and easily. Of course, specific individual tests can also be run manually.

For in-depth troubleshooting, fault localization, or control measurements in all repair states, the MotorAnalyzer3 offers further helpful tools such as:

• Surge tester
• Ohmmeter
• continuity test
• Megaohmmeter
• High voltage up to 6 kV
• Squirrel-cage rotor test with the RIC method
• DC Rotor Test
• sense of rotation E-Motor
• Sense of rotation stator
• Turn-to-turn fault detection
• neutral zone adjustment
• protective conductor resistance

AutoTest

• Fully automatic test
• Manual partial tests based on the fully automatic test

Tools

These useful measurement and adjustment tools facilitate typical tasks that arise daily during the repair of electric motors and winding goods.

The tools are not intended for documentation in the test protocol. Rather, they are used to detect or find faults, or to ensure that work steps have been executed correctly.

Do you have questions about operation? 

Then simply tap the i-symbol, which is located at the top right of every page. The MotorAnalyzer3 will then display i-symbols above the various symbols, graphics, tables, and functions. By tapping an i-symbol, you will receive the precisely relevant explanation, without having to search for a long time in an operating manual. 

The Explanations

Quickly understandable, structured explanations including graphics and symbols.

Configure AutoTest

The AutoTest configuration is performed via a simple checklist. To avoid illogical inputs, it also dynamically adapts to previously made selections. After entering the device under test type, the nominal voltage, and the test standard, the MotorAnalyzer3 automatically generates the test sequence plan for professional testing.

Test sequence generated by the configurator

For a three-phase device under test, the AutoTest runs between the following measurement points:

| 1 ‹ › 2 | 1 ‹ › 3 | and | 2 ‹ › 3 | or | 1+2+3 ‹ › GND |

The individual test methods are listed on the display from top to bottom. The AutoTest is also performed in this order.

The test parameters, such as test voltage level, tolerances, etc., were automatically pre-set by the configurator in a meaningful way. This plan can be used directly. However, it is also possible to adapt the test parameters to one's own requirements. To do this, swipe left on the display, and the AutoTest's test parameters will be displayed. Depending on whether the operator possesses basic or expert know-how, only the most important or all parameters will be shown.

Test

For each test method, an automatic evaluation determines whether the test result is within the specified tolerances. Depending on whether the test result is good or bad, a green or red bar is displayed.

Detailed views of the test results are available for each test method in the AutoTest. These can be accessed directly via the central navigation system.

Enter nominal, customer, and location data

The most important data of the device under test are displayed at the top center of the screen. These include the type and serial number of the E-Motor. These characteristics are used for saving, searching, and loading in the test result memory.

Additional information can be printed in the test protocol . This includes electric motor nominal data, customer data, and location data. This information can be entered before or after the test.

The configurator is used once for the first Maintenance test , for example, at an annual interval. All subsequent Maintenance tests are based on the last saved test result. The last Maintenance test is loaded from the results database, and this test plan is used as the basis for the next Maintenance test.

For the first Maintenance test, the type and serial number of the electric motor, as well as the electric motor nominal data, location data, and customer data, must be entered once.

This first Maintenance test is stored in the results database with date and time.

A test protocol can be created on a PC for each Maintenance test using PrintCom.

All test results are stored in the results database. For the next Maintenance test, the last performed Maintenance test is loaded.

To do this, switch to the content overview of the results database . The electric motor type and/or serial number is searched for and loaded using the quick search. The loaded test results from the last test are then displayed in the AutoTest. 

The start of the new test is now prepared.

The next Maintenance test is performed and stored with a new date in the test result memory. All previously performed Maintenance tests remain available, enabling a trend analysis. This helps to identify relevant 

changes in the device under test early and to react strategically – for example, by performing maintenance.

The Polarization Index (PI) is ideal for preventive maintenance. It indicates early signs of aging/insulation weaknesses in an electric motor.

The configuration of the AutoTest for the Incoming test during a repair is done via a simple checklist. To avoid illogical inputs, it dynamically adapts to previously made selections. After entering the device under test type, the nominal voltage, and the test standard, the MotorAnalyzer3 automatically generates the test plan for professional testing.

Creating a test plan with the configurator is convenient but not mandatory. The test plan can also be designed entirely by the user.

For the Incoming test, the electric motor type, the serial number of the electric motor for results storage, and, if applicable, the electric motor nominal data, location data, and customer data for the test protocol must be entered.

The Incoming test serves to determine the extent of damage and can be helpful in estimating repair costs for your customer. A test protocol can be created from the Incoming test using PrintCom on a PC.

All test results are stored in the results database. To perform the Outgoing test, the previously performed Incoming test is loaded.

To do this, switch to the content overview of the results database. The electric motor type and/or serial number can be found using the quick search. The loaded test results of the Incoming test are then displayed in the AutoTest. 

The start of the Outgoing test is now prepared.

The Outgoing test is performed and stored with a new date in the results database. A test protocol can be created from the Outgoing test using PrintCom on a PC.

AutoTest | Automatic testing up to 3 kV

For the automatic testing of a three-phase Motor, the three winding Connections and the electric Motor housing must be connected to the test device. The MotorAnalyzer3 analyzes the device under test fully automatically. The windings in stators should be ohmically and inductively symmetrical. If the deviations are too large, a fault is present. Additionally, the dielectric strength within the windings and to the laminated core is tested.

Resistance test

The Resistance test is performed with high accuracy using four-wire technology. The symmetry evaluation of the winding resistances or the comparison with a set value is performed automatically.

Winding shield temperature sensors integrated into the device under test can also be tested individually. If required, temperature compensation converts the resistance to 20 or 25 °C.

An optional ambient temperature sensor is required for this. Alternatively, a temperature determined with the help of a temperature measuring device can also be entered via the on-screen keyboard.

Inductance test

The Inductance test is run with high accuracy using four-wire technology. A test frequency between 50 and 60 Hz can be selected. Compared to various other inductance measurement methods, the Test current is significantly higher. This has the advantage that the laminated core is more strongly excited by the higher field strength, resulting in a more precise measurement result. The symmetry evaluation of the inductances or the comparison with a preset value is performed automatically.

Impedance test

The Impedance test is run with high precision using four-wire technology. A test frequency between 50 and 60 Hz can be selected. Compared to various other impedance measurement methods, the Test current is significantly higher. This has the advantage that the laminated core is more strongly excited by the higher field strength, resulting in a more accurate measurement result. The symmetry evaluation of the impedance or the comparison with a preset value is performed automatically.

capacitance test

The capacitance test takes place between the winding and the electric Motor housing. The Capacitance is compared with a preset value.

Insulation Resistance Test

The automatic insulation resistance test via the 4 measurement leads is performed with max. 3000 V, the manual test with 2 test tips with max. 6000 V.

The TEST VOLTAGE is defined via the configurator but can also be manually changed by the operator. If required, temperature compensation converts the insulation resistance to 40 °C. An optional ambient temperature sensor is required for this. Alternatively, a temperature determined with the help of a temperature measuring device can also be entered via the keyboard.

Polarization Index PI and DAR

The test serves to diagnose the insulation of stators, electric Motors, generators, transformers, cables, etc. The automatic test via the 4 measurement leads is performed with max. 3000 V, the manual test with two test tips with max. 6000 V.

The TEST VOLTAGE is defined via the configurator but can also be manually changed by the operator. If required, temperature compensation converts the insulation resistance to 40 °C. An additional room temperature sensor is required for this. The polarization index test, the insulation resistance test, and the step voltage test in combination with HV DC can be run consecutively.

high voltage test

The TEST VOLTAGE is applied to the device under test either directly or via a voltage ramp.

During the test, the insulation must not breakdown. A breakdown is detected by the resulting excess current.

Surge test up to 3 kV

For winding testing on stators, the MotorAnalyzer3 generates surge voltage pulses of up to 3 kV. This leads to the typical surge voltage oscillations. These are measured by the MotorAnalyzer3 in three test steps one after the other between the three electricalMotor-/stator connections. The three surge voltage oscillations are then automatically compared with each other or alternatively with a stored reference object. The basis of the comparison is the EAR method. It provides a precise statement about the symmetry of the windings. Asymmetries that are too large are automatically displayed as errors.

Surge test Peak-to-Peak up to 3 kV

The Peak-to-Peak method enables the measurement of a complete electric Motor. Starting from a low initial TEST VOLTAGE, the TEST VOLTAGE within a winding is gradually increased by a constant value up to the final TEST VOLTAGE. The deviation between the oscillation of the current TEST VOLTAGE and the preceding lower TEST VOLTAGE is determined as a percentage. Similar deviations should occur from stage to stage. However, if the deviation suddenly increases sharply, a voltage-dependent insulation fault is present in the winding.

The diagram clearly displays both the oscillations of the surge test and the percentage deviations of all measurements.

The highlight is that the surge test oscillation of each individual measurement can be graphically displayed individually afterwards. This allows the voltage value at which the winding insulation has broken down to be determined.

The equalized evaluation and graphical representation of the Peak-to-Peak analysis is patented by SCHLEICH!

Troubleshooting made easy

With these useful measurement and adjustment tools, the MotorAnalyzer3 simplifies the typical tasks that arise daily in the repair of electric motors and winding goods.

MultifunctionTools are not about documentation in the test protocol. They are about detecting, finding errors, or ensuring that work steps have been correctly executed.

Ohmmeter | continuity test

• Quickly measure ohmic resistance...
• Determine the start and end of a winding...
• Check the terminal assignment on a terminal board...
• Measure a diode...
• Measure a rectifier...
• Test brake Connections...
• Measure temperature sensors...

All this – and much more – are typical quick tests and measurements that must be run repeatedly during work in a variety of situations.

Continuity measurement with acoustic support. And the special thing about it: The MotorAnalyzer3 can do this not only for single-phase, but also for three-phase electric Motors/stators.

Megaohmmeter

• Quickly Test the insulation...
• Determine insulation resistance using a quick method – without standards and time limits.
• How good is the insulation on the commutator?
• How good is the insulation on the sliprings?
• Is the winding damp?
• Has the insulation of the winding improved after drying?

All this – and much more – are typical quick tests and measurements that repeatedly occur in the repair process.

high voltage test

• Quickly Test the dielectric strength...
• Quickly investigate where the breakdown occurs...
• Analyze with manual voltage setting at which voltage the breakdown occurs...
• Test phase insulations...
• Is the temperature sensor well insulated from the winding?
• If the electric motor electrically damaged during assembly or have been damaged in the electricalMotor Cable squeezed?

All these – and much more – are typical quick tests and measurements. Test the quality of your work before connecting the electric motor to the mains.

Of course, all this can also be done with an AC high voltage test device. However, if the insulation experiences breakdown during this process, it can lead to permanent damage. AC high voltage test is much more destructive than DC high voltage test. Therefore, always test with DC high voltage first!

Squirrel-cage rotor test | RIC-Test

Has a Squirrel-cage rotor a Broken rotor, it influences the inductance the phase under which the Broken rotor is currently located. For this reason, the inductance measured at a phase of the electrome. In this process, the rotor is rotated by one full revolution in several test steps at equal angular intervals. With a 2-pole electric motor with Broken rotor there are two inductance deviations over the entire revolution. With a four-pole electricMotor the deviation four times . 

DC Rotor Test

DC armatures are tested using the bar method. The resistance between all adjacent bars is measured. Commutators with up to 400 bars can be measured.

The first resistance measurement serves as a reference. All subsequent measurements are compared with this reference value. The bar graph shows the deviation between the bars.

Surge test up to 3 kV

• Quickly test the dielectric strength within a winding…
• Quickly investigate where the breakdown occurs...
• Analyze with manual voltage setting at which voltage it breaks down or if everything is GO…

All these – and much more – are typical quick tests and measurements. Test the quality of your work before connecting the electric motor to the mains.

Turn-to-turn fault localization on the stator or rotor

With the help of an induction test probe, the slots are localized where a turn-to-turn fault is present. For execution, the test probe is positioned directly over a slot and the measured value is stored. Subsequently, all other slots are tested. The measured value must not change significantly compared to the first measurement.

Broken rotor bar detection on the Squirrel-cage rotor

With the help of an induction test probe, the slots are localized where a Broken rotor is present. For execution, the test probe is positioned directly over a slot and the measured value is stored. Subsequently, all other slots are tested. The Test can only be run if the bars are not completely embedded in the rotor laminated core. If only one of the two double bars is interrupted in a double-bar rotor, the fault cannot be localized with this method. The measured value must not change significantly compared to the first measurement.

Neutral zone setting

Function to support the Adjusting the neutral zone on DC motors.  A bar display with center point immediately shows whether the brush bridge is in the neutral zone or needs to be adjusted. The graphical representation of the misalignment of the brush bridge makes it much easier to adjust the neutral zone. The operator immediately recognizes in which direction the carbon brushes have to be twisted to get to the neutral zone.

Rotating field test on the E-Motor

The electric motor shaft of a single-phase or three-phase motor is rotated manually to the right. It is tested whether the winding's rotating field is also rotating clockwise.

Rotating field Test on the stator

For the Test, the single-phase or three-phase stator is supplied with three-phase current from the outside. A rotating field probe located in the stator determines the sense of rotation of the magnetic field.

protective earth resistance test

The Test is carried out in conformity with standard DIN VDE 0701-0702 (Test after repair, modification of electrical devices – periodic Test of electrical devices).

The protective earth resistance test is performed with high precision using the four-wire method. DC voltage is used for measurement. The two test tips are held at the beginning and end of the protective earth conductor to be tested, for example, at the PE connection of the mains plug or the electric motor housing.

The measurement is automatically run in two test steps. In the second step, the polarity of the TEST VOLTAGE is reversed by the MotorAnalyzer. The higher of the two measured resistances is the protective conductor resistance.

Function and technology

• Fully automatic test sequence
• Manual test sequence
• Built-in 10 GB memory for tens of thousands of test results
• Real-time clock for storage with time and date 
• Input of E-Motor- and order data

safety

• Built-in plausibility checks for all inputs
• Safety and warning messages
• Built-in explanatory help texts per input
• foot-switch Connection

Communication

• Bluetooth

• WIFI connectivity for remote training