Testing of installed, de-energized electric motors

Stator test

Electric motor testing

Interim checks during electric motor repair

Testing of DC armatures

Electric motor maintenance

During maintenance work, the e-Motor with a user-friendly "AutoTest". 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 connecting cables to the electric motor.

Any discrepancies that arise can also be addressed retroactively. Manual individual inspections can be carried out. It is therefore perfectly suited for fault analysis.

The car test includes the following checks:

• Resistance
• impedance
• Inductance
• Capacity
• Insulation resistance, DAR, PI
• High voltage
• peak voltage

The regular maintenance measurements are collected in the results memory and can thus be accessed throughout the entire lifespan of the electric motor, e.g. for trend analysis.

After transfer to the PC software PrintCom, the Results will be documented in a comprehensive test report.

Electric motor repair

AutoTest is excellent when it comes to electric motor repair. suitable for:

• Entrance examination
• Interim exams
• Final examination

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

For more in-depth troubleshooting, fault localization, and 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 using the RIC method
• DC Rotor Test
• Direction of rotation E-Motor
• Stator rotation direction
• Winding closure search
• Neutral zone adjustment
• Protective conductor resistance

Car Test

• Fully automated testing
• Manual partial inspections based on the fully automated inspection

Tools

These useful measuring and adjusting tools facilitate typical tasks that arise daily in the repair of electric motors and wound components.

The tools are not about documentation in the test report. Rather, they are about recognizing or finding errors, or ensuring that the work steps were carried out correctly.

Do you have any questions about how to use it? 

Then simply tap the "i" symbol, which is located in the top right corner of every page. And then it will show... MotorAnalyzer3 over the various symbols, graphs, tables and Functions are indicated by the "i" symbols. By tapping Clicking the "i" symbol provides the exact explanation you need, without having to search through a user manual. 

The explanations

Quickly understandable, structured Explanations including graphics and symbols.

Configure AutoTest

The AutoTest is configured via a simple questionnaire. To prevent illogical entries, it also dynamically adapts to previously made selections. After entering the test object type, the nominal voltage, and The MotorAnalyzer3 automatically generates the test standard. Test procedure plan for proper testing.

Test sequence generated by the configurator

The AutoTest runs on a three-phase test object between the following measuring points:

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

The individual test methods are displayed from top to bottom. Listed below. The AutoTest will also be performed in this order.

The test parameters, such as test voltage level, tolerances, etc., were automatically and sensibly preset by the configurator. This plan can be used directly. However, it is also It is possible to adjust the test parameters to your own preferences. To adjust the settings, swipe left on the display to show the AutoTest parameters. Depending on whether the user has basic or expert knowledge, only the most important parameters or all parameters will be displayed.

Test

For each test method, an automatic evaluation is performed to determine whether the test result falls 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 AutoTest. These can be accessed directly via the central navigation system.

Enter name, customer and location data

The most important data is displayed at the top center of the screen. The test object's data is displayed. This includes the type and serial number of the electric motor. These characteristics are used for saving, searching, and loading the test result memory.

Further information can be printed from the test report. This includes electric motor specifications, customer data, and location data. These can be entered before or after the inspection.

The configurator is used only once for the first maintenance check, For example, it is used at an annual interval. All subsequent maintenance checks are based on the most recently saved check result. The last maintenance check is used in this process. The results were loaded from the memory and this test plan was used as the basis for the next maintenance test.

During the first maintenance check, the type and serial number of the electric motor, as well as the E-motor nominal data, the location data and the customer data, must be entered once.

This first maintenance check is stored in the results memory with the date and time.

PrintCom can create a test report on a PC for every maintenance check.

All test results are stored in the results memory. The next maintenance test will be carried out using the... Last maintenance check performed loaded.

This is done by going to the content overview of the results memory. changed. The quick search looks for and loads the electric motor type and/or serial number. The loaded The test results from the last test are then displayed in AutoTest. 

The start of the new exam is now prepared.

The next maintenance check will be performed and recorded in the check results memory with a new date. All previously performed maintenance checks remain available, allowing for trend analysis. This helps to identify relevant 

to detect changes to the test object at an early stage and to react strategically – for example by a Maintenance is being carried out.

The polarization index (PI) is ideal for preventive purposes. Maintenance. It provides early warning of signs of aging/insulation weaknesses in an electric motor.

The AutoTest is configured for initial inspection during a repair using a simple questionnaire. To avoid illogical input, it also dynamically adapts to previously made selections. After The MotorAnalyzer3 automatically generates the test plan based on the test object type, the nominal voltage and the test standard. for a professional examination.

Generating a test plan with the configurator is convenient, but not mandatory. You can also design the test plan entirely yourself.

During the initial inspection, the electric motor type, the serial number of the electric motor for result storage, and, if applicable, the electric motor nominal data, the location data, and the customer data for the test report must be entered.

The initial inspection serves to determine the extent of the damage and can be helpful in estimating repair costs for your property. To assess customers. The initial inspection can be used with PrintCom can create a test report on a PC.

All test results are stored in the results memory. To perform the outgoing check, the previously performed incoming check is loaded.

This is done by going to the content overview of the results memory. The system is switched. The quick search function finds the electric motor type and/or serial number. The loaded test results from the initial inspection are then displayed in AutoTest. 

The start of the final examination is now prepared.

The outgoing inspection is performed and the results are stored in the results memory with a new date. A test report can be generated from the outgoing inspection 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 test object fully automatically. The windings at Stators should be symmetrical in terms of resistance and inductance. If the deviations are too large, a fault is present. Additionally, the dielectric strength within the windings and at 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 The target value is set automatically.

Winding protection temperature sensors built into the test object can also be tested individually. be checked. The temperature compensation adjusts the resistance to 20 or 25 °C if necessary. 

An optional ambient temperature sensor is required for this. Alternatively, a temperature determined using a thermometer can also be entered via the on-screen keyboard.

Inductance test

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

Impedance test

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

Capacity check

The capacitance test takes place between the winding and the electric motor housing. Capacity is compared to a target value.

Insulation Resistance Test

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

The test voltage is set via the configurator, but can also be changed manually by the operator. Temperature compensation is applied if required. Insulation resistance is reduced to 40 °C. An optional ambient temperature sensor is required for this. Alternatively, a temperature determined using a thermometer can also be entered via the keypad.

Polarization index PI and DAR

The test is used to diagnose the insulation of stators, electric motors, generators, Transformers, cables, etc. Automatic testing via the 4 measuring leads The test is performed with a maximum of 3000 V, the manual test with two test probes with a maximum of 6000 V.

The test voltage is set via the configurator, but can also be set by The operator can change the settings manually. Temperature compensation recalculates the insulation resistance to 40 °C if required. This requires an additional room temperature sensor. The polarization index test, the insulation resistance test, and the step voltage test in combination with HV DC can be performed sequentially. 

High-voltage testing

The test voltage is applied either directly or via a voltage ramp. the test object was created.

The insulation must not bleed during the test. A bleed will detected by the resulting overcurrent.

Impulse voltage 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.

Peak-to-peak surge voltage test up to 3 kV

The peak-to-peak method allows for the measurement of a complete electric motor. Starting with a low initial test voltage, the test voltage within a winding is gradually increased by a constant value until the final test voltage is reached. 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 step to step. However, if the deviation suddenly increases sharply, a voltage-dependent insulation fault is present in the winding.

The diagram shows both the oscillations of the impulse voltage and the Percentage deviations of all measurements are clearly displayed.

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

The standardized evaluation and graphical representation of the peak-to-peak analysis is patented by SCHLEICH!

Troubleshooting made easy

With these useful measuring and setting tools, the MotorAnalyzer3 simplifies the typical tasks that arise daily in the repair of electric motors and wound components.

Multifunction tools are not about documentation in the test report. They are about detecting and finding errors, or ensuring that the work steps were carried out correctly.

Ohmmeter | Continuity test

• Quickly measure the ohmic resistance…
• Determine the beginning and end of a winding…
• Check the terminal assignment on a clipboard…
• Measuring a diode…
• Measuring a rectifier…
• Check brake connections…
• Temperature sensors measure…

All of this – and much more – are typical quick checks and measurements that need to be carried out repeatedly during work in a variety of situations.

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

Megaohmmeter

• Quickly test the insulation…
• Determine insulation resistances quickly – without standards or time constraints.
• How good is the insulation on the collector?
• How good is the insulation on the slip rings?
• Is the coil damp?
• Has the insulation of the winding improved after drying?

All of this – and much more – are typical quick checks and measurements that occur repeatedly during the repair process.

High-voltage testing

• Quickly test the voltage resistance…
• Let's quickly investigate where it's breaking through...
• Analyze the manual voltage setting to determine at which voltage it breaks through…
• Check phase insulation…
• Is the temperature sensor well insulated from the winding?
• If the electric motor was electrically damaged during assembly or if the electric motor was used in the electric motor,Motor Cable squeezed?

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

Of course, you can also do all this with an AC high-voltage tester. But if the insulation breaks down during this process, it can lead to permanent damage. AC high-voltage testing is much more destructive than DC high-voltage testing. Therefore, always test with DC high voltage first!

Short-circuit conductor test | RIC test

If a squirrel cage rotor has a rod break, this influences the inductance of the phase under which the rod break is currently located. For this reason, the inductance is measured at a phase of the electrome for testing. In this process, the rotor is rotated by one full revolution in several test steps at equal angular intervals. In the case of a 2-pole electric motor with rod breakage, there are two inductance deviations over the entire revolution. With a four-pole electricMotor the deviation is detected four times . 

DC Rotor Test

DC armatures are tested using the lamella method. This involves measuring the resistance between all adjacent lamellae. Collectors with up to 400 lamellae can be tested. 

The first resistance measurement serves as a reference. All subsequent measurements are taken with This was compared to a reference value. The bar graph shows the deviation between the slats.

Impulse voltage test up to 3 kV

• Quickly test the voltage resistance within a winding…
• Let's quickly investigate where it's breaking through...
• Analyze the manual voltage setting to determine at which voltage it whether it breaks through or whether everything is okay…

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

Winding failure location on the stator or rotor

Using an induction probe, the grooves in which a A short circuit is present. To perform the test, the probe is placed directly over a The groove is positioned and the measurement is saved. Subsequently, all further steps are performed. Grooves checked. The measured value must not change significantly compared to the first measurement. 

Rod breakage detection on the squiere rotor

An induction loop probe is used to locate the slots where a bar break is present. To perform the test, the probe is positioned directly over a slot and the measurement is recorded. Subsequently, all other slots are checked. The measurement must not change significantly compared to the first measurement. This test can only be performed if the bars are not fully embedded in the rotor lamination stack. If only one of the two double bars in a double-bar rotor is broken, the fault cannot be located using this method.

Neutral zone setting

Function to assist in setting the neutral zone on DC motors.  A beam display with center 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 can immediately see in which direction the carbon brushes need to be twisted to get to the neutral zone.

Rotating field test on the E-Motor

The shaft of a single-phase or three-phase electric motor is turned clockwise by hand. It is then checked whether the rotating magnetic field of the winding is also clockwise.

Rotation field test at the stator

For testing, the single-phase or three-phase stator is supplied with three-phase current from an external source. A rotating field probe located inside the stator determines the direction of rotation of the magnetic field.

Protective conductor resistance test

The test is carried out in accordance with the standard DIN VDE 0701-0702 (Testing after repair, modification of electrical equipment – ​​Periodic testing of electrical equipment).

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

The measurement is performed automatically in two test steps. In the second step The polarity of the test voltage is reversed by the motor analyzer. The higher of the two measured resistances is the protective conductor resistance.

Function and Technology

• Fully automated testing process
• Manual testing procedure
• Integrated 10 GB memory for tens of thousands of test results
• Real-time clock for storing time and date 
• Input of E-Motor- and order data

Safety

• Built-in validation checks for all inputs
• Safety and Warning Messages
• Integrated explanatory help texts for each input
• Foot switch connection

Communication

• Bluetooth

• Wi-Fi connectivity for remote training