ALL-TEST IV PRO 2000 USER MANUAL

The ALL-TEST IV PRO 2000 comes complete with re-charger, test - leads, instruction-book and one-year full
warranty. It is protected by a sturdy hard case.

Software and software connection cable are included.

Most instructions on how to operate the ALL-TEST™ appear on the screen. Field tests have shown that operators
with
limited experience in using other test instruments, such as amp-meters, ohm meters and meg-ohm-meters, normally
become fully proficient in how to use the ALL-TEST IV PRO™ 2000 in less that 2 hours of self-training.

SPECIFICATIONS:

Testing Range:
R = Resistance. 0.001 – 999 Ohms. Reads in ohms and in % difference of reference.
Z = Impedance. 3 -1660 Ohms. Reads in ohms and in % difference of reference.
Fi = Phase Angle. 0 - 90 Degrees. Relative. Measures time difference between the current and voltage provided by
instrument. Shows in degrees and in % difference of reference.

Insul = Megometer. 500 Volts: 0 - >99 Mohm. Size: 4.8 * 9.92 * 2”. (122 * 252 * 50 mm).
1000 Volts: 0 - >99 Mohm. Weight: 1.7 lb. (0.75 kg).
Batteries 6 AA Nickel Metal Hydride.
Power Cons.: Current 0.130; 0.195 A
I/F = -50% to + 100%
L = Inductance: 1 – 9999 mH.
C = Capacitance: 0.1µF - 20 0µF.
Hz = 100 - 200 – 400 – 800 Hz standard.

Measurements guaranteed to be with 1% accuracy.

STANDARD EQUIPMENT
• Back-lit LCD screen with 4 lines and 4 *20 characters.
• Batteries installed.
• Battery charger 115 volts. Optional 220 volts for outside USA.
• Testing-cables with clips.
• Attaché type hard case with foam liner.

ACCESSORIES AVAILABLE
• Transmission cable from instrument to PC
• Software for up and down loading, storing and working in PC.

One year limited warranty on parts and labor.

ATIVNOV2001 1
INSTRUMENT WARNINGS AND CONSIDERATIONS

The following is a list of considerations for equipment life and accurate data collection:

Ensure that all power has been removed from the circuit being tested, including static power stored in capacitors –
Discharge all capacitors being tested.

Some electric motors will still generate a charge back into the motor circuit, if they are still rotating after shutdown.
High voltages being introduced into the analyzer may damage it.

Attaching the ALL-TEST to live voltage may destroy the instrument and void the warranty.

Do not attempt to replace the batteries. Contact your ALL-TEST IV PRO™ 2000 distributor or BJM CORP, ALL-
TEST Division at 800 442-2562 to have the battery pack replaced.

Do not open the instrument. Electrostatic charges may damage surface mount electronics. Please contact your
vendor or BJM CORP, ALL-TEST Division for an authorized repair center.

While testing equipment ensure that one leg of any power factor correction capacitors or lightning arrestors are
disconnected to avoid data errors.

General Safety Considerations

Following are general safety considerations for using the ALL-TEST IV Pro™ 2000 Motor Circuit Analyzer:

The ALL-TEST IV Pro™ 2000 is an off-line motor tester, all power and residual power must be disconnected. It
provides an intrinsically safe method of testing your electric motors.

Follow all safety rules of your company and OSHAct for off-line testing methods, including appropriate Personal
Protective Equipment (PPE). Improper or unsafe operation of the equipment is the sole responsibility of the user.
.
For MCA testing, the ALL-TEST IV Pro™ 2000 sends out a low voltage, high frequency signal not harmful to the
technician or electronic equipment (Variable Frequency Drives and Soft Starts). However, electronic equipment and
personnel must observe appropriate safety considerations (disconnect electronic equipment) when using the Meg-
Ohm test.

ATIVNOV2001 2
INDEX

Page 1. STANDARD EQUIPMENT SPECIFICATIONS

Page 2. INSTRUMENT WARNINGS AND CONSIDERATION

Page 3. INDEX

Page 4. DESCRIPTION OF FUNCTIONS TURNING THE INSTRUMENT ON BATTERIES AND BATTERY

CHARGER

Page 5. MAIN MENU

HOW TO: WRITE IN, OR CHANGE NAME, DATE AND TIME
AUTO MODE
CONNECT TEST LEADS AND MEASURE
CHOSE 500 OR 1000 VOLT FOR INSULATION TO GROUND TESTING
DC MOTORS
INSULATION TO GROUND (MEG-OHM-METER) TEST (see also MANUAL, page 6)

Page 6. MEASUREMENT, TEST RESULTS (see also page 8 under ANALYZING RESULTS)
DIFF
REF
SAVE NAME

Page 7. MANUAL (testing)

EDIT LIBRARY

Page 8. SEARCH NAME

COMMUNICATION

Page 9. TRANSFORMER TESTING

DC ELECTRIC MOTOR TESTING
ROTOR TESTING
DATA COLLECTION NOTES AND RECOMMENDATIONS

Page 10. Continuation of DATA COLLECTION NOTES AND RECOMMENDATIONS

CONTACT INFORMATION
ALL-TEST PHILOSOPHY
ANALYZING MEASUREMENTS AND CHANGE
R, Z, L, Fi, C

Page 11. Continuation of ANALYZING MEASUREMENTS AND CHANGE

INS
I/F (Current/Frequency)
TECHNICAL SUPPORT

Pages 12 –16. SAMPLES OF DEMOS 1-5 AND COMMENTS

Attachment 1: TRANS01: TRANSFORMER TESTING- 3-PHASE TRANSFORMERS

Attachment 2: TRANS02: TRANSFORMER TESTING- 1-PHASE POLE-MOUNT TRANSFORMERS
Attachment 3: MOTOR01: MOTOR TESTING- 3-PHASE FAULT DETECTION EXAMPLE
Attachment 4: MOTOR02: MOTOR TESTING – DC MOTOR TESTING

Note: All-Test users can request updated and new materials by visiting our website: www.alltest.cc .

ATIVNOV2001 3
DESCRIPTION OF FUNCTIONS
ON/OFF, which turns the instrument on and off.
DC is the port for the re-charger. Com is the communication-port.
Turn on the backlight to illuminate the screen. This is very important when you are using the instrument in dark
places.
However, should you not need it, keep it off at all times to save on the batteries.

Looking at the face of the ALL-TEST, the arrows work pretty much as the arrows and the mouse does on a
computer.
The OK is used for enter or continue. MENU will take you back to the prior menu.
Pressing it twice will take you back to the first menu as shown on the screen.
Pressing down left and right arrows simultaneously takes you back to MAIN MENU from any place.
INSUL is insulation test.
Moving to the top of the instrument. The ports with the blue line in between are used for all measuring except for the
meg-ohm-meter. These ports are marked with a red line in between.

TURNING THE INSTRUMENT ON.

When you first turn the instrument on, the text “ALL-TEST PRO” and “BATTERIES” shows. Five stars after the
battery indicates a fully charged battery.

BATTERIES AND BATTERY CHARGER

When starting the unit and you see only two stars after BATTERY, the instrument will flash a warning reading
“LOW BATTERIES, RECHARGE”. The batteries should then be recharged for an hour or two.
The battery charger is equipped with a trickle charger, which means that after it has fully loaded the ALL-TEST, it
shuts down and only trickle-feeds the batteries to keep them topped off. To further safeguard the batteries, the ALL-
TEST
IV is equipped with a heat sensor that breaks the power at a certain temperature. The light on the charger turns
from a steady red to blinking red when the batteries are fully charged.
There are 6 AA (1.2 V) batteries operating the instrument and 1 internal battery for memory function.
WARNING: Use only nickel metal hydride rechargeable batteries (Ni-mH;1.2V; 1100 mAh).

ATIVNOV2001 4
MAIN MENU

The first menu is called the MAIN MENU. The first time you use the instrument you should install the name (of
your choice) as well as the date and the time. The clock is a 24-hour clock, which means that midnight is 24-hundred
hours and one o’clock in the afternoon is 13-hundred hours. Place your cursor where you want to make the change,
press OK, select the characters using arrows up and down and pressing OK between chosen letters. When finished
press MENU RETURN. You can change the date and the time the same way.

AUTO MODE
AUTO MODE automatically tests Resistance, Impedance, Inductance, Phase Angle and Insulation to Ground. The
measurements taken in AUTO MODE can be saved under chosen name. Up to 14 characters.
First, decide if you are going to use the ground insulation tester in the 500 or the 1000-volt mode. Place the cursor
on INS, press OK. To change from 500 to 1000, or vice versa, keep cursor on 1and hold down OK until it changes.

If you choose to do an Insulation Test to ground directly (without using the auto-mode), you select 2 by pressing
arrow up, and then pressing OK.

After choosing the voltage for Insulation to Ground, press MENU to return to AUTO. With cursor on AUTO press
OK. Shown in text: “COMP TEST LEADS; Short Test Leads. Press any key and wait. This is to offset the
resistance in the test cables.

“Ready connect the target”, comes up. Press any key to continue.

For three phases, mark the terminals 1, 2 and 3. Connect 1 and 2. Press OK. The screen reads: “connect winding one
and press any key to continue...” Should you have a bad connection, or open winding, the instrument will keep
flashing “WAITING….”, give 0 result in resistance and/or impedance, or show on the screen: “BAD RESULT!
Press left and right arrows to restart”. Make sure that you have a good connection and use the re-measure command
to re-test.

Repeat the procedure for 1 to 3 and 2 to 3. The screen then asks you if you want to do an Insulation Test.

Insulation Resistance to ground (Meg-ohm-meter) test.

If you chose yes, the screen will tell you to move the test-leads to the Insulation ports on the instrument, marked
with a red line. Keep red lead on one phase and move the other to ground. The screen tells you to “Hold down
INSUL button until result is obtained”. Reading over 99 Mohm are shown aσ> (larger than 99). If it is under 99 the
readout will show with decimals down to 0 Mohm.

The instrument now asks you, do you want to SAVE? Here you can also chose REFerence or DIFFerence.
Before we do that we can scroll down and see what the other numbers are telling us.

ATIVNOV2001 5
MEASUREMENTS, TEST RESULTS

The first screen shows the resistance, impedance and phase angle. By scrolling down, the result of the
Inductance, I/F and Insulation test is read.

Now look at DIFF. This is the difference in percentage between windings of the Resistance and the
Impedance, showing the just taken measurements. The instrument compares windings 1 to 2, 2 to 3 and 3 to1. Press
menu to return to first screen.

REF (REFERENCE). If a motor has been saved earlier, you can display motor with resistance and
impedance readings, using AUTO or NAME search command. If you choose NAME, simply press on
NAME and enter the name.

In AUTO search, the ALL-TEST looks for a motor by sameness of resistance in 2%, 5% and 10%. If a motor
is showing within 2%, the same will show in 5% and 10%.

The first line for a measurement, when you scroll down, is shown with an arrow behind . These lines contain
the previous measurements. The lines below are the newest measurements. However, the first time a
particular motor is tested both lines will show the same results. Scroll to the right to see all motors. Press
MENU and “no more found in 2%” will show. “Press OK to continue.” Repeat action to look for motors
within 5% and then 10%.

To see all measurements you will have to go to (EDIT LIBRARY) or NAME SEARCH.

SAVE NAME. Place cursor on SAVE NAME and press on OK. Enter name by scrolling up and down to
desired letter or digit. Press OK after each. You can use up to 11 characters. Press MENU after last
character. After you have installed the name you will be asked to “Register the number of phases and
horsepower”. You will then be asked to “Save name YES or NO, choose YES or NO and return to menu .

ATIVNOV2001 6
MANUAL.
Scroll to MANUAL press OK - choose resistance, impedance, inductance, capacitance or phase angle. For
insulation go to INS situated after “Search Name.

RESISTANCE.
Make sure the test leads are in the right ports. Place cursor on R and press OK. Follow instructions on screen and
short test-leads, and then connect to target and press OK. Note: If you are testing large coils or motors with 100
milli-ohm resistance, or less, take caution getting a good connection with clean metal to clean metal contact. Use
“Remeasure” several times after connecting between each phase.

IMPEDANCE
Go to Z, press OK. Connect to target. The instrument will read “measuring” and then “measuring phase angle”. The
reading here shows you the measured impedance in ohms and what frequency the instrument used when measuring.

INDUCTANCE.
Place cursor on L and press OK. Connect test leads. As soon as the leads are connected the measuring will begin.

PHASE ANGLE.
Place cursor on Phase angle, connect to target and press OK.

CAPACITANCE.
Place cursor on C, connect to target and press OK.
Note: When measuring a capacitor, make sure that any residue charge is eliminated by shortening the terminals. For
capacitance range see written specifications.

INS.
You can perform the Insulation to Ground test from INS situated after NAME SEARCH. Place cursor on INS and
press OK. Follow instructions on screen. Measurement larger than 99 Mohm is shown as >99. Any number under 99
is shown in Mohm and with decimals.

EDIT LIBRARY.
In EDIT LIBRARY you can actually change anything you want: the name, the date, the time and all the
measurements. Scroll by using right arrow and when you come to the motor you want to change, press OK. You will
now have Number of Phases showing. If you want to change this, scroll up or down until desired number and press
OK. For changing NAME, HP, DATE, TIME and RESISTANCE and IMPEDANCE between 1, 2 AND 3 continue
to scroll to the right.

To change PHASE ANGLE and MEG, start at first screen showing name of motor. The cursor is now blinking on
the no. of Phases (F). Scroll down one, the cursor is now blinking on M1, press OK. Scroll to the right to get to
PHASE ANGLE and MEG and number of motors.

EDIT Phase M1 is now showing PHASE ANGLE. If you want to edit, press OK and scroll up or down until desired
number. Then press OK again. By scrolling to the right you get to phase 2 and 3 and lastly MEGGER.
By scrolling all the way to the right you get to EDIT number of Motors. Here you can see how many motors are
stored in memory. By changing this number, for example from 50 to 40, you will delete the last 10 motors entered.
By setting the number to 0 (Zero) before starting a days work you will only see that days motors before going home.
This can be useful when using our PC Software.

WARNING: Make sure that you really want to delete any motors before proceeding. Should you use the ALL-TEST
SOFTWARE, make sure that you have saved these motors in a database.

Press left and right arrows simultaneously to speed getting back to MAIN MENU.

ATIVNOV2001 7
SEARCH NAME.
Go to program, press OK, and select the characters by scrolling up and down. Press OK after each character. After
last character has been OK’d, press MENU RETURN button. You will be asked: Find name?
Answer YES or NO. If YES, motor will show on screen.
Note: You should put in at least 3 of the first digits of the motor name.
To see if several motors have the same or similar name, (starting with the same first 3 digits), scroll to right.

Should you want to see comparisons between tests, stop on desired motor showing the right date of test you are
looking for. Under the name of the motor, the difference between the very first and the very last tests are shown in
percentage of difference. To see stored measurements scroll down one. Resistance and Impedance will show on first
screen with oldest test on top and with an arrow behind. All tests of the same motor are saved in order of date saved.
The measurements with the arrow behind, shows the date measurements were taken. The second line always shows
the very last measurements taken on the same motor, from all dates saved. This measurement is shown across all
motors with the same name, regardless of date saved.

Scroll to the right to find the latest save (by date) of the motor you are looking up. Go to the left to find the first save
of this motor. This way you can follow a change by seeing the DIFF(erence) gradually change between dates saved.
Note: Disregard readings of other motors showing but not chosen and which only shows because of closeness in
name.

If motor (that you are sure that you have previously saved), is not found, check if you have hidden any motors in
EDIT number of Motors. See EDIT number of motors under EDIT LIBRARY.)

COMMUNICATION
Only used with AT SOFTWARE. See separate SOFTWARE USER Manual.

ATIVNOV2001 8
TRANSFORMER TESTING
The ALL-TEST IV Pro™ 2000 Motor Circuit Analyzer may be used to test transformer windings in the same
fashion that motor windings are tested. All of the same principles and procedures apply. However, due to the
inherent design of a transformer, the analyzer may induce very small currents into the windings that are not in the
test circuit and create erroneous test results due to reflected impedance.

To eliminate, or at least minimize the effects of other transformer windings, all open leads should be shorted
together then to ground (i.e.: Transformer core or transformer ground). By shorting these coils, the winding under
test (primary or secondary) can be easily tested. See attachments 1 and 2 (Tech notes TRANS01 and TRANS02).

DC ELECTRIC MOTOR TESTING

The ALL-TEST IV Pro™ 2000 Motor Circuit Analyzer can be used to troubleshoot DC electric motors and the
readings can be saved. In order to test a DC motor, you must raise all but two sets of brushes 900 from each other.
Test the armature by rotating it.

The fields can be tested by splitting the fields and testing between the connections (i.e.: Test F1 to F2 and F3 to F4
(in some cases the shunt fields (S1 and S2) or the armature windings may be below .001 Ohms. Impedance
measurements may be closely matched between each test, as well.

ROTOR TESTING
Three phase squirrel cage rotors can be tested with the ALL-TEST IV Pro™ 2000 Motor Circuit Analyzer using the
manual inductance testing method. See the “3 –phase motor troubleshooting guidebook for detailed procedures.

Turn the rotor so that the shaft keyway is in the 12 O’clock position.

Following a test on the motor winding to ensure that it is OK, place the test clips on motor leads 1 and 2 (this can
also be performed from the disconnect or motor control center).

Take an inductance reading and record it on a notepad.

Turn the shaft in even increments, the more the better (See the troubleshooting guide).

The readings will not be identical but should result in a pattern as the shaft is rotated. If the pattern varies, there are
rotor, casting, or air gap problems. Rotor and casting problems show as a sudden change in one location on the
motor while air gap problems change consistently around the rotor.

DATA COLLECTION NOTES AND RECOMMENDATIONS

Following are observations from over 15 years of MCA with the ALL-TEST™ line of motor testers:

When performing PdM on three phase electric motors, try to place the rotor in the same position each time (i.e.: 12
O’clock position) which will reduce changes from data collection to data collection due to rotor influence. You may
also use the ALL-Test III along with the ALL-Test IV. See atttachment 3 (Tech note MOTOR01).

When the initial test is performed, if there is a variation in inductance of 5 to 15% between phases, perform a rotor
test in order to determine if the variation is due to the rotor or if there is a rotor fault.

The upper end of testing is in electric motors with under .001 ohms in each phase (the lower limit of resistance).

Train yourself to always collect data from 1-2, 1-3, and 2-3 which will allow for consistency between readings. In
this way, defects can be identified as to the phase in which they occurred. For instance, an increase in impedance in
1-2 and 1-3 occurs, then you should check the phase 1 connections.

ATIVNOV2001 9
ALL-TEST PHILOSOPHY
Knowing that the reactance of a motor to any type of measuring or test is dependent on not only the size and voltage
of a motor, but in particular the design and construction, our philosophy is to make instruments that:
• are easy and safe to use
• shows fault(s) immediately
• shows any change over time
• looks at many different measurements for analyzing
• test virtually any size motor, coil, generator or transformer
• light weight and portable

ANALYZING CHANGE
Some of our competitors are treating testing and analysis of electrical motors as a “black magic art”, when in reality
it can be very straightforward. Some companies even tell you that they can unfailingly tell you exactly what ails a
motor after looking at a test result from only a few measurements. We claim that this is ambiguous. Only by further
investigation and measuring the different components can you be sure as to really know what the fault is. Please see
further explanation in the paragraphs below.

Our approach is very simple. We know that, if any change occurs in any one of the several measurements taken by
the ALL-TEST, the change is never for the better, but a degradation is taking place. Unless, of course, a repair or
modification has taken place between tests. By analyzing the size of the change you can now determine when and
how to take action. A deteriorating Insulation to Ground situation, for example, will normally require immediate
attention as this fault can be very dangerous and because the insulation to ground normally deteriorates rapidly.

A turn-to-turn or coil-to-coil fault, on the other hand, can creep up over a longer period of time. This gives you a
chance to schedule your downtime.

If you are not familiar with how impedance, inductance and frequency/current effect a motor, we recommend that
you review on the subject. It will help you when analyzing any change in your particular motor.

R -Resistance is the Direct Current, resistance measured in Ohms. It should measure the same across all phases or
fields. Any difference shows that there is a problem. Difference can be due to “over-winding”, corrosion, bad
connections, etc. Note: If you are testing large coils or motors with 100 milli-ohm resistance, or less, take
caution getting a good connection with clean metal to clean metal contact. Use “Remeasure” several times after
connecting between each phase.

Z- Impedance is the Direct Current and Alternating Current Resistance in a coil or winding.
It includes DC Resistance, inductive reactance and capacitive reactance. It is measured in Ohms. For a three
phase motor all three measurements should read the same, or within 5%. A larger difference indicates a fault.
The larger the difference in measurement between windings, the larger the fault. Zero means “open” winding, or
no continuity. See also I/F below.
Note: A coil or winding can have a severe turn-to-turn fault but show “good” when “megging”. It can also show
a severe Ground Insulation fault but show perfectly OK turn-to-turn.

L- Inductance is dependent on the amount of turns and of the material in a spool or coil’s core. The value is a
measurement of how large the Electro-magnetic capacity is. It is measured in milli-Henrys. All phases should
measure the same. Differences can be due to shorts, or heavy contamination of dirt, water, etc. in motor. A small
difference can be due to the position of the rotor.

Phase Angle. It shows the reactive behavior of electrical fields by measuring the time difference between voltage
and current, as emitted by the instrument.
This is not to be confused with Power Factor, which is measured on a “live” motor.

C- Capacitance. It is measured in mF or F (microfarads or farads). A capacitor should be tested separately from a

motor. Capacitance test from phase to ground can also be valuable when looking for heavy contamination of
dirt, water, etc., in a motor.

ATIVNOV2001 10
INS- Insulation (to Ground) Test. Measured in Meg-Ohms.
A reading of 0.25 Mohm, or less, means that the motor is unsafe and that it should be taken out of
commission immediately. A very good insulation should read >99 Mohm. Lower readings indicate
weakness in insulation but can also be due to build-up of dirt or grease in the motor. A motor can
show good insulation to ground but fail an impedance test, and vice versa.

I/F- Current/Frequency, primarily testing for coil-to-coil or turn-to-turn faults, needs a little explaining. The
frequency sent by the instrument is automatically doubled. The change on the current (when the frequency is
doubled) is shown in percentage of change.
If all three phases are the same, or within one digit, there is no problem at hand. A small difference
between windings can be due to the positioning of the rotor or the fact that the instrument shows
whole numbers in AUTO mode.
If one phase is lower than the other two - by two, three or more digits, you have a problem. The wider
the difference the larger the fault. Should you have zeros you have an open - you have no connect
For a single phase, the I/F reading should be between -50 and -15 for a good coil. For an open
winding the reading will be 0 (zero).

NOTE: A small difference can be due to the position of the rotor.

TECHNICAL SUPPORT: BJM CORP, ALL-TEST Department, 1-800-442-2562 or fax 1-860-399-7784.

Email: alltest@Bjmcorp.com Website: www.bjmcorp.com

ATIVNOV2001 11
ANALYZING MEASUREMENTS AND CHANGE: SAMPLES AND COMMENTS

For additional information on data analysis, interpretation and applications, see Motor Circuit
Analysis: Theory, Application and Energy Analysis, by Dr. Howard W. Penrose, Ph.D., ISBN #
0-9712450-0-2. The book is available through BJM Corp or your ALL-TEST™ distributor.

Data interpretation of collected ALL-TEST IV PRO™ 2000 data can be performed through the
ALL-TEST Advanced Analysis software programs: HAL Junior™ 2.0 (or later) and the Electric
Motor Circuit Analysis Tool (EMCAT™ - Available after March, 2002).

Troubleshooting Rules

Following are the basic rules for troubleshooting with the ALL-TEST IV PRO™ 2000:

Shorted Windings:

Shorted windings can be evaluated by viewing the phase angle and I/F readings from the
instrument on similar coils or between phases:

Phase Angle (Fi) – The phase angle should be within 1 digit of the average reading. For
instance, a reading of 77/75/76 would be good because the average reading is 76. A reading of
74/77/77 would be bad.

Current Frequency Response (I/F) – The current frequency response should be within 2 digits
of the average reading. For instance, a reading of –44/-45/-46 would be good. A reading of
-40/-44/-44 would be bad. However, a reading such as -42/-44/-44 should be considered suspect.

Type of winding fault – The type of winding fault can be determined by viewing the pattern of
Fi and I/F. However, if either reading is bad, there is a winding fault that must be evaluated.

Shorted Winding Table

Pattern Most Likely Fault
Both I/F and Fi are bad Turn to turn short in the same coil
I/F bad and Fi good Phase to phase short
I/F good and Fi bad Coil to coil short in the same phase

Winding Contamination and Rotor Position

The position of the rotor within the electric motor will cause a natural phase unbalance (See Tech
Note Motor 01). Winding contamination will also cause phase unbalances. The difference
between the two can be evaluated quickly by looking at the pattern of impedance and inductance.

Rotor Position – Rotor position unbalances can be evaluated by looking to see if the inductance
and impedance values are fairly balanced. For instance, if there are inductances of 17/18/19 and
impedances of values 24/26/29, then the unbalance is due to rotor position. This may also be the
case if the inductances are 5/5/5 and the impedances are 8/9/8.

ATIVNOV2001 12
Winding Contamination – Can also be found as overheated (burned) windings. These
conditions are the result of changes to the insulation due to breakdown of the insulation system.
The faults show as a change of impedance and the relationship between impedance and
inductance result in un-parallel readings. For instance, if there are inductances of 10/11/12 and
the impedance has values of 16/14/13, then they are not parallel and the most likely fault is in the
windings as contamination or overheated insulation.

Insulation Resistance – The insulation resistance (Meg-Ohm readings) will show a breakdown
of insulation between the winding conductors and ground. The latest edition of the IEEE Std.
43-2000 states that the insulation resistance of windings should fall in the following ranges:

Insulation Resistance Readings

Type of Insulation Insulation Resistance Values
All insulation systems prior to 1974 1 Meg-Ohm + 1 Meg-Ohm/kV
Random Wound Motors > 5 Meg-Ohms
Form Wound Motors and DC Armatures > 100 Meg-Ohms

Loose Connections

Loose connections or glazing on contacts will show as resistance unbalances. The maximum
resistance unbalance should be 5%.

Sample Test Results

Following are several examples of motor test results that are commonly found:

Shorted Windings from Motor Control Center on 15 Horsepower Motor Due to Contamination

The following motor was operating in a food processor. Tests were performed from the motor
control center located ~500 feet from the motor. It was a 15 horsepower, 1800 RPM milling
motor.

T1-T2 T1-T3 T2-T3

R 0.954 1.054 0.9
Z 52 96 56
L 20 19 22
I/F -44 -39 -39
Fi 80 83 85
Ins >99M

As noted, the I/F and Fi are greater than 2 points and 1 point respectively. This indicates a turn
to turn short within a coil. Also, the impedance and inductance readings are not parallel,
indicating winding contamination or an overheated winding.

ATIVNOV2001 13
Loose Connection and Rotor Related Phase Unbalance in a 75 Horsepower Motor

Tests performed on a 75 horsepower electric motor in a hot, dirty environment revealed the
following readings:

T1-T2 T1-T3 T2-T3

R 0.275 0.494 0.158
Z 37 32 33
L 7 6 6
I/F -40 -41 -41
Fi 72 72 72
Ins >99M-Ohms

The high readings show when looking at T1 to T2 and T1 to T3, indicating a possible loose
connection on T1. The impedance and inductance readings show an unbalance. However, the
unbalances are roughly parallel, indicating that the phase unbalance is due to the rotor position.
The loose connections were found in the motor control center at the starter and corrected.

Contaminated Windings in a 200 Horsepower Motor

A 200 Horsepower, 1800 RPM motor tested at a rock quarry in an area with high moisture
content. Tests were performed ~ 1000 feet from the motor at the motor control center:

T1-T2 T1-T3 T2-T3

R 0.034 0.035 0.038
Z 13 15 7
L 2 3 3
I/F -41 -40 -41
Fi 66 66 66
Ins >99M-Ohms

As noted, there is a definite non-parallel phase unbalance between impedance and inductance.
The motor windings were found to be damp – water in the motor housing.

Rotor Coil Fault in 8,000 Horsepower, 200 RPM, 13,800 Volt, Synchronous Motor

Rotor coil faults can be difficult to find in large assembled synchronous rotors. In this case, the
synchronous motor would not start. Several readings were taken, one with the rotor in one
position and a second reading with the rotor moved about 5 degrees of rotation. The second
reading was to determine if the winding fault was in the motor or rotor.

(test results on next page)

ATIVNOV2001 14
 First Reading
T1-T2 T1-T3 T2-T3
Resistance 0.322 0.319 0.319
Impedance 189 181 190
Inductance 37 38 37
Phase Angle 81 85 83
I/F -42 -49 -46
Insulation #.#

Second Reading
T1-T2 T1-T3 T2-T3
Resistance 0.318 0.316 0.321
Impedance 190 182 190
Inductance 37 38 37
Phase Angle 83 86 81
I/F -45 -49 -44
Insulation #.#

Note that the readings, in particular Fi and I/F, change as the rotor position is changed. This
indicates that the fault lies within the rotor. The motor was disassembled and the fault found to
be four of thirty-six rotor coils that had overheated coils that shorted. The overheating can be
found as the impedance to inductance relationships are not parallel.

Good vs Bad Rotor Tests

Rotor test results taken in inductance should be symmetrical. In most cases, the results will by
sine-waves. Indentations indicate casting voids (aluminum cast rotors), high resistance rotor
connections (copper-alloy rotor bars) or broken rotor bars. Indentations that impact the top of
the sine-wave will effect the operation of the motor.

Good 200 Horsepower, 3600 RPM Motor

0.1065
0.106
Inductance

0.1055
0.105
0.1045
0.104
0.1035
1 2 3 4 5 6 7 8 9 10 11 12
Rotor Position

ATIVNOV2001 15
 200 Horsepower, 3600 RPM Motor with Casting Void that Effects Operation

0.1065
0.106

Inductance
0.1055
0.105
0.1045
0.104
0.1035
1 2 3 4 5 6 7 8 9 10 11 12
Rotor Position

400 Horsepower, 1800 RPM Motor With Casting Void and Rotor Eccentricity
1.2

1.15

1.1

1.05

0.95

0.9

0.85

0.8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

The 400 Horsepower example shows a casting void (note the sine-waves on the right side) and
the sine-waves arc as the readings go from left to right.

Additional Case Studies

Additional case studies, etc. can be found in Motor Circuit Analysis: Theory, Application and
Energy Analysis, ISBN# 0-9712450-0-2, by Dr. Howard W. Penrose, Ph.D., which can be
obtained through BJM Corp, ALL-TEST™ Division or your nearest ALL-TEST™ distributor.

ATIVNOV2001 16
BJM CORP ALL-TEST™ Tech Note: Motor01
Basic Knowledge ⇒
q Problem Example
q Improvement Example
______________________________________________________________________________

Theme: Motor Testing – 3-Phase Fault Detection Example

_____________________________________________________________

Description

This Tech Note supplements information found within the 3-Phase Motor Troubleshooting
Guidebook concerning stator and rotor fault detection. This example will describe the basic
steps in determining motor, rotor or no fault detection in assembled 3-phase design B, single
speed, electric motors.

It is important to note that a “perfect” 3-phase motor is very difficult to find based upon
manufacturing tolerances, etc. In other instances, motors may have a particular difference in
design in order to meet special applications. In both cases, with the rotor mounted in the motor,
it is necessary to perform additional steps to isolate rotor or stator faults.

Initial Readings

In a few cases, some motors may exhibit unusual levels of unbalance. This could occur for a number of reasons,
including: 1) stator pole to rotor bar ratio and position; 2) stator winding design (lap versus concentric coil); 3) other
tolerance-related issues including rotor casting voids. If a series of unusual readings are detected with the ALL-
TEST IV PRO™, there are several ways of isolating the cause. One method requires the use of an ALL-TEST III™
in concert with the ALL-TEST IV PRO™, the other method involves a short series of additional tests using the
ALL-TEST IV PRO™.

Sample Initial Readings

Reading T1- T1- T2-
T2 T3 T3
Resistance .272 .273 .272
Impedance 47 53 58
Inductance 9 10 11
Phase Angle 73 72 71
I/F -43 -42 -41

Based upon these readings, the motor should be exhibiting failure signs such as electrical noise or a lack of torque.
Following we will provide two examples of how to determine if and what type of fault exists.

ALL-TEST III™ and ALL-TEST IV PRO™ Tandem Method

One method of separating the stator from the rotor when troubleshooting is to use an ALL-TEST
III™ in concert with your ALL-TEST IV PRO™:

1. Connect the ALL-TEST III™ to your first set of windings (T1-T2) and rotate the shaft
until the highest reading is obtained.
2. Take your first ALL-TEST IV PRO™ reading (first winding) then stop.

ATIVNOV2001 17
 3. Connect the ALL-TEST III™ to your second set of windings (T1-T3) and rotate the shaft
until the highest reading is obtained.
4. Take your second ALL-TEST IV PRO™ reading (second winding) then stop.
5. Repeat for your third winding. If the final results still show an unbalance, the stator
should be suspect, if they are balanced, the rotor should be checked using the rotor testing
steps for either the ALL-TEST III™ or ALL-TEST IV PRO™. If both the stator and
rotor test good, then the unbalance is due to the motor design and should be noted.

ALL-TEST IV PRO™ Method

Using the ALL-TEST IV PRO™, a short series of tests may be performed in order to determine
whether the unbalanced readings are due to the rotor, stator or design. The steps are
straightforward:

1. Note the position of the rotor after saving the original readings. Move the rotor 90
degrees from its original position and retake the readings in the same order that they were
originally taken.
2. Reference the previous reading and note if the unbalance has shifted with the rotor
movement. If it has, or if you are uncertain, retake the measurements at 180 degrees
from the original position.
3. If the readings remain unbalanced in the original position, the stator windings are most
likely faulted, if the readings shift with the rotor position, perform a rotor test as outlined
in the motor troubleshooting guide.

Shifting Readings Example Maintained Readings Example

T1- T1- T2- T1- T1- T2-
T2 T3 T3 T2 T3 T3
Impedance 0 47 53 58 Impedance 0 47 53 58
deg deg
Inductance 0 9 10 11 Inductance 0 9 10 11
deg deg
Impedance 90 53 58 47 Impedance 90 47 53 58
deg deg
Inductance 90 10 11 9 Inductance 90 9 10 11
deg deg
Impedance 180 58 47 53 Impedance 180 47 53 58
deg deg
Inductance 180 11 9 10 Inductance 180 9 10 11
deg deg
Note: The readings will not be exact, this Note: The readings will not be exact, this
is just an example is just an example

ATIVNOV2001 18
General Notes

Note 1: In few cases do large unbalances relate to original design. In most instances, these
unbalances can be related to defects due to operation or manufacture. The motor may seem to
operate OK, but have a large number of casting voids or high resistant rotor bars that will reduce
the effectiveness of the motor to produce torque.

Note 2: An accurate assembled impedance unbalance may be obtained, for energy and reliability
purposes, by taking 4 to 12 rotor positions then measuring impedance at each position. Average
the readings and determine the average phase unbalance. This can be used in conjunction with
BJM CORP’s Impedance Unbalance Calculator or “Motor Circuit Analysis for Energy,
Reliability and Production Cost Improvements”1 to determine annual costs. It may also be used
in MotorMaster+ Version 3.02 Enhanced for determining repair versus replace cost benefits.

1
Penrose, Dr. Howard W., Western Energy Magazine, September/October 2000 Edition
BJM CORP ALL-TEST™ Tech Note: Motor02
⇒
Basic Knowledge
q Problem Example
q Improvement Example
______________________________________________________________________________

Theme: Motor Testing – DC Motor Testing

_____________________________________________________________

Description

This Tech Note describes the basic steps necessary to test and troubleshoot DC electric motors
using the ALL-TEST IV Pro™ 2000. The DC motors discussed include: series connected, shunt
wound and compound wound standard DC motors that have access to brushes and visual access
to the commutator. This Tech Note assumes an understanding of the construction, nomenclature
and general operation of DC motors by the user.

Winding Types

There are three basic winding types for DC motors:

1. Series Motor

Series motors consist of interpole and

armature windings and a series winding.
The winding resistance is generally very
low and the motor requires a load when it
operates or it will “run-away.” The
A1 A2 S1 S2 windings are marked A1 and A2 for the
interpole(s) and armature leads and S1 and
S2 for the series coil. These are high-
torque motors normally used as traction
and locomotive drives.

2. Shunt Motor

The shunt motor has a winding in

parallel to the armature winding and
interpoles. This type of motor has
good speed regulation and reasonable
starting torque. The interpoles and
F1 A1 A2 F2 armature windings are usually low-
resistance while the shunt winding has
many turns of smaller wire giving it a
relatively high resistance. The field
windings are normally labeled F1 and
F2 for single voltage and F1-F2 and F3-F4 for dual voltage.
 3. Compound Motor

The compound motor combines the strengths of

both the series and shunt motors. The leads are
normally labeled as shown in the previous
descriptions.
F1 A1 A2 S1 S2 F2

Testing DC Motors

Following are the types of testing available for each motor:

1. Series Connected DC motor: The true method for testing this type of motor is by trending,
looking for changes, particularly in I/F and phase angle (which are not as temperature
dependant as the other readings) from reading to reading. A bar-bar armature test can be
performed using either the ATF11 armature fixture or the existing brushes.
2. Shunt Connected DC motor, single voltage: Same testing as for the series connected DC
motor (see 1).
3. Shunt Connected DC motor, dual voltage: In this case, a comparison test can be performed
using F1 and F2 as the first winding compared to F3 and F4 as the second winding, then A1
to A2 as the third winding. The bar to bar test may be performed, as well.
4. Compound Connected DC motor: Combines the testing methods shown in 1, 2 and 3. In
addition, a continuity check using impedance should be performed between the series coils
and the field coils to make sure that there are no shorts between the two.

Testing Steps – Trending

For trending purposes, the auto mode of the ALL-TEST IV Pro™ 2000 can be used.

1. From the drive or at the motor terminals, select Auto Mode.

2. Test the Available Field Windings (F1-F2, or F1,F3 – F2,F4, or F1-F4, as appropriate).
If possible, split the winding (if 4-field leads are available) in order to provide
comparative readings, as winding 1 and winding 2 in the ALL-TEST.
3. Test the series winding, as appropriate. If only one field winding is available, use
winding 2 (if it is a series winding, use winding 1, of course) and test S1-S2. If testing
using winding 3, test S1 to A2, as appropriate (that will take a reading of the armature
and series windings).
4. Test the armature through A1-A2, and store in winding 3.
5. Store and compare to future readings. Resistance, inductance and impedance will vary
based upon winding temperature. Ensure to take readings at the appropriate repeatable
times, such as just after operation or after a cool-down period (room temperature).
Testing Steps – Troubleshooting Field and Series Windings

1. Separate all leads.

2. If possible, compare F1 and F2 to F3 and F4 in shunt and compound motors. There
should be no more than a 3% difference in resistance, impedance or inductance, with the
phase angle being within 1 degree and the I/F being no more than 2-digits from each
other.
3. Test the Series field looking to see if the I/F is greater than “-50” and compare to
previous readings, if possible.
4. If it is a compound motor, test between the series and shunt fields. If there is any
continuity, the windings have failed.

Armature Test – Bar to Bar

The key to testing the armature is a bar to bar measurement of impedance. There are two basic
methods. If there is good access to the commutator, use the ATF11 armature fixture. Set the
ATF11 to cross as many bars as possible, lift all brushes, then perform the test covering all of the
commutator bars 360 degrees around the commutator. If unable to access the commutator with
the ATF11, lift all but two brushes 90 degrees from each other (use both brushes if it is a two –
brush motor) and clip the ALL-TEST leads to the connections for these brushes.

1. Visually inspect the brushes and commutator looking for evidence of overheating,
burning, contamination, excessive wear, etc.
2. Mark the first bar being tested using a non-conductive marking. If the ATF11 is being
used, select either the right or left point as the start. If brushes are being used, use the
leading edge of one of the two brushes as the reference point. In many cases, the brush
will cross multiple bars. As you progress around the commutator, the ATF11 will move
one bar at a time, or the leading edge of the reference brush will move to the edge of one
commutator bar at a time.
3. Use the manual mode of the ALL-TEST and select “Z” (impedance). As each set of bars
are tested, use the “remeasure” selection in the “Z-test.” Write down each result
watching for impedance, and changes in frequency (shown on the right side of the screen
– test frequency may change if a short is detected).
4. Look for a pattern that may result in a flat line or a gradually increasing then decreasing
set of readings. This can be done visually or by entering the data into Excel and graphing
it. Readings that deviate more than 3% from the pattern may indicate shorted turns or
bad connections in the commutator.
BJM CORP ALL-TEST™ Tech Note: Trans01
Basic Knowledge ⇒
q Problem Example
q Improvement Example
______________________________________________________________________________

Theme: Transformer Testing – 3 Phase Transformers

_____________________________________________________________

Description

The ALL-TEST IV PRO™ 2000 may be used to test any type of 3-Phase commercial and utility transformers in a
similar fashion that electric motor windings are tested. The true sine wave generated by the ALL-TEST™ that
provides unequaled motor rotor testing, coupled with the type of connections found in transformers, will cause
traveling currents that will provide erroneous test results. This can be easily avoided with a test procedure that can
be used on any type of three phase transformer connection. In many cases, this can be used as a “screening” test
prior to performing the specific testing required within many utilities. Avoiding one costly test series on a bad
transformer will usually pay for the ALL-TEST™.

Procedure

In order to test a three-phase transformer, you must ground ALL of the leads on the other side of the
transformer that you are not testing. This means that you must test the primary, with all of the secondary
leads grounded, then the secondary, with the all of the primary leads grounded. If you ground only one
lead, you will get poor test results. Ground straps or cables must be sized to handle the output voltage
that will be generated due to the output of the ALL-TEST IV PRO™ 2000.

The general procedure is as follows:

1. De-Energize and disconnect primary and secondary of transformer to ensure that stray voltages are
not present that will harm the operator nor the ALL-TEST™. The appropriate safety requirements
for Lock-Out/Tag-Out and testing de-energized equipment apply.
2. Attach grounding straps to the secondary of the transformer, including the neutral (usually identified
as Xo). Ensure that the grounding straps or cable are attached to a true earth ground.
3. Ensure that the transformer switch, if applicable, and once the transformer has been isolated, is in the
“on” or “operating” position.
4. Perform the Auto test per the ALL-TEST IV PRO™ 2000 manual. Ensure that the connection points
are as clean as possible. If the ALL-TEST™ shows “Bad Result,” the simple resistance of the circuit
is too low. Save the results. When testing, the normal sequence is H1 to H2, H1 to H3, then H2 to
H3. If the readings are unbalanced, remeasure them. If the readings are not repeatable when
remeasured, check the ground connection and retest.
5. Attach the grounding straps or cable to all the primary leads of the transformer then to a true earth
ground. Follow the instructions for the secondary as shown in step 4, using X1, X2, and X3.

Test Results

Test results on a good transformer may vary, especially when the simple resistance drops below 0.250
Ohms. Failed transformers tend to have very dramatic results and, if you are trending, readings will
increase fairly rapidly in unbalance to failure. If you are trending critical transformers, we recommend
testing at least monthly.
 Table 1: Good 2,500 kVA, 28,800:4,300 Table 3: Bad 500 kVA, 13,800:240 Volt Pad
Volt Pad Mount Transformer: Primary Mount Transformer: Primary
Reading T1- T1- T2- Reading T1- T1- T2-
T2 T3 T3 T2 T3 T3
Resistance 3.703 3.623 6.648 Resistance 116.1 88.20 48.50
Impedance 220 217 218 Impedance 4972 1427 1406
Inductance 87 86 86 Inductance 7911 2267 2237
Phase Angle 88 88 88 Phase Angle 23 21 20
I/F -49 -49 -49 I/F -33 -29 -29

Table 2: Good 2,500 kVA, 28,800:4,300 The 500 Volt insulation resistance
Volt Pad Mount Transformer: Secondary reading on the primary side was 9.132
Reading T1- T1- T2- M-Ohm. The primary of this winding
T2 T3 T3 had most likely blown to ground and
Resistance .103 .100 .096 damaged the secondary. Readings could
Impedance 15 14 14 not be performed on the secondary as a
Inductance 2 2 2 result.
Phase Angle 75 75 75
I/F -48 -48 -49

The following test result recommendations are for reference only, results may vary on some
transformers.
Resistance: Should not be more than 5% unbalanced when testing above 0.250 Ohms, but may be
as high as 7.5% unbalanced when below 0.250 Ohms.
Impedance: Should not be more than 5% unbalanced. Failed transformers will tend to have
unbalances over 100%.
Inductance: Should not be more than 5% unbalanced.
Phase Angle: Should be within one digit from each other.
I/F: Should be no more than two digits from each other.
Note: Readings that have a definite “shift” as shown in Table 4 should be flagged for further
testing. (Notice inductance, phase angle and I/F as compared to impedance and resistance)

Table 4: Questionable Transformer

Example
Reading T1- T1- T2-
T2 T3 T3
Resistance 3.929 3.843 4.002
Impedance 162 164 159
Inductance 32 32 31
Phase Angle 78 78 77
I/F -44 -44 -45
BJM CORP ALL-TEST™ Tech Note: Trans02
⇒
Basic Knowledge
q Problem Example
q Improvement Example
______________________________________________________________________________

Theme: Transformer Testing – 1 Phase Pole-Mount Transformers

_____________________________________________________________

Description

The ALL-TEST IV PRO™ 2000 may be used to test any type of 1-Phase pole-mount
transformers. The true sine wave generated by the ALL-TEST™ that provides unequaled motor
rotor testing, coupled with the type of connections found in transformers, will cause traveling
currents that will provide erroneous test results. This can be easily avoided with a test procedure
that can be used on any type of single phase pole-mount transformer connection. In many cases,
this can be used as a “screening” test prior to performing the specific testing required within
many utilities. Avoiding costly test series on a bad transformers will usually pay for the ALL-
TEST™.

Procedure

In order to test a single phase pole-mount transformer, you must ground ALL of the leads on the other
side of the transformer that you are not testing. This means that you must test the primary, with all of the
secondary leads grounded, then the secondary, with the all of the primary leads grounded. If you ground
only one lead, you will get poor test results. Ground straps or cables must be sized to handle the output
voltage that will be generated due to the output of the ALL-TEST IV PRO™ 2000.

The general procedure is as follows:

6. De-Energize and disconnect primary and secondary of transformer to ensure that stray voltages are
not present that will harm the operator nor the ALL-TEST™. The appropriate safety requirements
for Lock-Out/Tag-Out and testing de-energized equipment apply.
7. Attach grounding straps to the secondary of the transformer, including the neutral (usually identified
as Xo). Ensure that the grounding straps or cable are attached to a true earth ground.
8. Ensure that the transformer switch, if applicable, and once the transformer has been isolated, is in the
“on” or “operating” position.
9. Perform the Auto test per the ALL-TEST IV PRO™ 2000 manual. Ensure that the connection points
are as clean as possible. If the ALL-TEST™ shows “Bad Result,” the simple resistance of the circuit
is too low. Save the results. When testing, the normal sequence is to perform all three phases on the
primary [ H1 to H2, H1 to H2, then H1 to H2]. If the readings are not repeatable when remeasured,
check the ground connection and retest.
10. Attach the grounding straps or cable to all the primary leads of the transformer then to a true earth
ground.
11. Perform the Auto test by placing the black lead on the center post of the secondary and the red lead
on the left post (the center post is usually the center tap of both transformer secondary windings).
Use the first winding for the ALL-TEST™ winding 1 and winding 2 automatic test. If the readings
are not repeatable, within 1%, check the ground connection and re-test. Use the winding 3 test
between the center post and the right post. Save the test results. [X2 to X3, X2 to X3, then X2 to X1]

ATIV1101 25
 Figure 1: Pole Mount Transformer Test Locations

X
X
X

Test Results

Because of the lack of an internal comparison on the primary, users with many pole mounted
transformers of the same type may wish to compare the primary results with other transformer
results. Otherwise, the primary readings would be the I/F (must be between –15 and –50),
insulation resistance (>100 M-Ohms), and continuity.

On the secondary, the two windings should have resistance, impedance and inductance readings that are
within 5% of each other, a phase angle that is within one degree, and an I/F that is within two points of
each other (ie: -44, -45, -44). Usually a failure is indicated by a massive unbalance between the phases.

Table 1: Good Pole-Mount Transformer

Reading X2- X2- X2-

X3 X3 X1
Resistance 0.014 0.014 0.012
Impedance 78 78 77
Inductance 15 15 15
Phase Angle 26 26 27
I/F -49 -49 -49

ATIV1101 26