ALLTEST Pro LLC Basic Motor Testing Because The

ALL-TEST Pro, LLC “Basic Motor Testing: Because The Job You Save May Be Your Own!” Mike Schneider Regional Sales Manager 860 -391 -3877 mikes@alltestpro. com www. alltestpro. com © 2006 -2014 ALL-TEST Pro, LLC All Rights Reserved

Who We Are • ALL-TEST Pro, LLC • Established 1983; privately held • Worldwide sales (more than 16, 000 instruments sold) and service • World leader in de-energized & energized test instruments for Predictive Maintenance, Trouble Shooting and Quality Control of electric motors, generators, alternators, coils and windings • Customers range from multi-national manufacturers to service providers • Proven method, revolutionizing the industry

Who We Are • We make hand-held, field-portable, battery operated electric motor testing instruments. • These instruments are designed for the end-user to quickly and easily be able to identify developing electrical issues within a motor system. • A simple 2 -minute test will give you a complete picture of your entire motor system’s electrical health whether used for trouble-shooting or predictive maintenance.

ATP Markets Served (All Products) • • • Petro-Chemical Automotive Manufacturing • Mining Basic Metals (steel, aluminum, • copper, etc. ) • Pulp/Paper Manufacturing • Wood Products • Cement Manufacturing • High Technology • Manufacturing • Bottling Plants • Refining • Pharmaceutical HVAC Water Treatment & Waste Water Treatment Power Generation Building Maintenance Food Processing Aerospace Drilling (Oil & Gas) General Manufacturing Logistics Marine Industry …And MANY more!

Few of Our Most Known Customers ABB Caterpillar Gerdau Ameristeel Pfizer Abitibi Bowater Chrysler Hershey Pratt & Whitney Alcoa Cirque Du Soleil Holcim Qatar Petroleum Aluminerie Alouette Conoco Phillips Honda North America San Antonio Water Anheuser-Busch Delta Electric IBM Saudi Aramco Mobil Refinery Arcelor. Mittal Dofasco Steel International Paper Shell Arch Coal Domtar Kimberly Clark Siemens Atomic Energy Canada Du. Pont Lafarge Southern CA Edison BASF Electric Boat Lockheed Martin Space Coast Launch Bayer Ensco Lyondell Sunoco Boehringer Ingelheim Equistar Miller Coors Suwannee American Cement Boeing Evergreen Energy Morton Salt Syncrude Bosch Exxon Mobil Chemical NASA Thyssen. Krupp BP Fed. Ex Nestle Texas Instruments Bristol Aerospace Ford New Brunswick Power Tinker Air Force Base Brunei Liquefied Natural Gas GE Sensing & Inspection Nucor Total Burullus Gas Company Genentech Panama Canal Trans. Alta Canadian Advanced General Mills Pasadena Refining Systems UPS Canadian Natural Resources General Motors PEMEX US Coast Guard Cargill Georgia Pacific Petromont US Steel

Basic Motor Testing

Construction of a Motor (Stator)

Construction of a Motor (Rotor)

How a motor works

What is Motor Circuit Analysis (MCA)? In equipment with three phase windings all phases should be identical (same # turns, same wire size, coil diameter, etc. ). Consequently, all characteristics of the windings should also be similar. If a change occurs in any one of these characteristics, the change is never for the better, (windings do not repair themselves) as degradation is taking place. By analyzing the amount and relationships of the change it is possible to identify the cause of the degradation. Once the cause and the severity of the degradation are known it is now possible to determine the necessary action. Note: MCA can also be used on Transformers, Generators, Single-phase AC, DC & Servo Motors

Motor Circuit Analysis (MCA) 3 -Phase AC Motor example: Each “phase” is made up of the same gauge wire, the same length, wrapped the same number of times (or “turns”) to create “coils” and the same number of “coils” to create “phases” which make up the “windings” of the stator. Therefore, all of the electrical characteristics of each phase should be identical. Using Motor Circuit Analysis (MCA) we compare the electrical characteristics of each phase and find an average of the readings in each category. Then we find any deviation from average and the greater the deviation, the more severe the problem.

VERY Basic Motor Theory • In a healthy 3 -phase motor, all winding measurements should be balanced – All Balanced = Good – One or more Unbalanced = Not Good • Look at and compare multiple measurement parameters to determine the reason • It’s that simple!

Motor Circuit Analysis (MCA) In addition to an “Insulation-to-Ground” test, these are the 7 electrical parameters being measured: 1. 2. 3. 4. 5. Resistance Impedance Inductance Fi (phase angle)* I/F (current frequency response)* Test Value Static (TVS )* 7. Dynamic Stator and Rotor Signatures* 6. *Details will be provided later in this presentation

Common Testing Devices What do YOU do when a motor fails? What tools do you currently use to determine if the motor is “good” or “bad”? If you’re like most people, you probably have a Meg. Ohm Meter and a Digital Multi-meter. . .

Basic Motor Testing Let’s look at an actual motor test on an installed motor where the drive had tripped… Megger >999 MΩ PHASE Resistance (R) 1 -2 1 -3 14. 2 Ω 2 -3 14. 2 Ω The electrician used a Meg. Ohm Meter and Digital Multi-meter to acquire these results. So, what would you say about the condition of this motor?

Basic Motor Testing Obviously, the problem is with the Drive and not the Motor, right? So, would you replace the VFD or the Motor? The electrician was relying on a “Megger” (Insulation-to. Ground test) and a Digital Multi-meter (Resistance test). He was looking at 2 factors that affect the motor. And they both indicate that there’s nothing wrong with this motor…as far as the instruments can tell.

Common Testing Devices – Doctor? Would you go to a doctor who ONLY uses a stethoscope and thermometer for diagnostic testing? Why not? The doctor could diagnose a FEW issues but what if you: Break your leg? Have high cholesterol? Have high blood pressure? Have cancer? All of these things will get worse if not diagnosed and treated properly.

Common Testing Devices Using a Meg. Ohm Meter and Digital Multimeter for “motor testing” is like a doctor trying to diagnose what’s wrong with you by just using a stethoscope and thermometer. Pretty effective at determining if your motor is “alive” or “dead” (i. e. , shorted to ground) or has connection issues. But completely worthless if there is anything else wrong with your motor.

Common Testing Devices I doubt your doctor would be comfortable making a diagnosis without using all of the tools at their disposal and looking at all of the factors… Doctors need to get the diagnosis right – in some cases it might be the difference between life and death – YOUR life and death! The result for the doctor could be a lawsuit or loss of their license – and loss of their job!

Common Testing Devices Whether you want to believe it or not, YOU are the doctor your company relies on to diagnose motor issues Quickly and Accurately! Enough lost production or downtime on YOUR watch and…YOU’RE looking for a new company where you can mis-diagnose motor issues!

Basic Motor Testing Here are the test results again… Megger >999 MΩ PHASE Resistance (R) 1 -2 1 -3 14. 2 Ω 2 -3 14. 2 Ω Did you replace the Drive or the Motor?

Basic Motor Testing Using Motor Circuit Analysis (MCA) this is what that same electrician found… Megger >999 MΩ PHASE Resistance (R) Impedance (Z) Phase Angle (Fi) Current/Frequency Response (I/F) 1 -2 1 -3 2 -3 14. 2 412 421 427 64° 63° 64° -29 -28 -29 If you replaced the motor, you cost your company time and money both in the cost of the motor and the fact that you’ll have to replace the drive when it trips again. (“Oops! It wasn’t the motor after all!”)

Basic Motor Testing Guess what? The same electrician had an identical motor trip the drive on a different line. Megger >999 MΩ PHASE Resistance (R) 1 -2 1 -3 17. 1 Ω 2 -3 17. 1 Ω Now what? Is it the Drive or the Motor?

Basic Motor Testing Using Motor Circuit Analysis (MCA) this is what that same electrician found… Megger >1 MΩ PHASE Resistance (R) Impedance (Z) Phase Angle (Fi) Current/Frequency Response (I/F) 1 -2 1 -3 17. 1 438 444 64° 63° -29 -28 2 -3 17. 1 532 39° 8 If you said, “Motor” you get a gold star!

Basic Motor Testing Using a Meg. Ohm Meter and Digital Multi-meter ONLY in both cases would have left our electrician completely blind. Since the problem wasn’t a short-to-ground or a connection issue he would have been GUESSING! The only job who can guess every day (and still be employed) is the Weatherperson. Without Motor Circuit Analysis (MCA) he would have had no basis to make an informed decision. Looking at ALL of the factors that affect a motor electrically is the only way to determine if the problem lies with the Drive or the Motor. Fortunately, our electrician had a tool for Motor Circuit Analysis (MCA).

Meg-Ohm-Meter & Volt/Ohm Meter When Used for Electrical Motor Testing* Ground Faults Internal Winding Faults ** Open Connection Rotor Faults Contamination Meg-Ohm. Meter Yes No No No Yes Volt/Ohm Meter No No Yes No No * Common electrical testing instruments **Winding coil faults: turn-to-turn & coil-to-coil

ALL-TEST PRO Motor Circuit Analysis Instruments (MCA) MCA Ground Faults Internal Winding Faults ** Open Connection Rotor Faults Contamination Yes Yes Yes **Winding coil faults: turn-to-turn & coil-to-coil

Motor Reliability Questions

Motor Reliability Questions • Have you ever installed a new motor and had it fail on start up or run a short time and then fail? • Have you ever found a motor in spares inventory and its electrical condition was unknown? • Have you ever received a repaired motor and it didn’t run? • Do you sometimes solve a motor system problem by just replacing parts?

Motor Reliability Questions • Do you ever get a “no problem found” report from your motor shop? • What do you do with new motors when they arrive? Do you install them right away? What’s the typical warranty on new motors? • How much $$ do you spend to rewind motors every year? • How many GOOD motors do you throw away every year?

Why Motor Circuit Analysis (MCA)? MCA gives you the ability to troubleshoot and monitor the ELECTRICAL health of your motors whether installed or uninstalled. MCA gives you the ability to assess a motor’s immediate condition and determine whether that motor is headed for an electrical failure (or has failed!) This can also be used as a baseline for a long-term Predictive Motor Maintenance program. The reason you use Infrared Imaging, Vibration Analysis and Ultrasonic Testing is to eliminate unscheduled downtime. Motor Testing gives you one more “bullet for your gun” that allows you to “see” what you never could before – developing ELECTRICAL issues in your motors. OR…confirm that the reason your motor failed is the motor, drive, a cable or a connection issue.

Electrical Insulation System Winding Faults Can Develop Between: Between • Turns In A Single Coil • Coils In The Same Phase • Phases And Ground

Electrical Insulation System Insulation degrades under so called TEAM stresses –Thermal (high temperature) –Electrical (partial discharge) –Ambient (moisture, chemicals) –Mechanical (magnetic force/vibration)

Common Motor Failures (Electrical) Rotor* ü Cracked Rotor Bars ü Broken Rotor Bars ü Eccentricity (uneven Air Gap between Rotor and Stator) ü Contamination (gunk in the Air Gap – grease, cement dust, steel filings, gypsum dust, etc. ) Within the windings* ü Turn-to-Turn short ü Coil-to-Coil short ü Phase-to-Phase short *Some of these will cause the drive to trip but WON’T result in motor failure until they’re severe enough! Windings to Frame *Short to Ground *Fatal condition/Motor is “Dead” and will not run

Common Motor Failures ≈ 47% Of Motor Faults Are Electrical and only about 5% of those are a SHORT-TO-GROUND!

Common Motor Failures (Electrical)

Common Motor Failures (Electrical) con’t

Technology Comparison (De-energized) PQ Cntrl Conn Cable Stator Rotor Air Gap Ins Brgs Vibe Align Load VFD Off-Line (De-energized) Testing High Pot - - - - X - - - Surge Test - - X - - - - Meg-ohm Meter - - - - X - - - Ohm Meter - - L - - - - PI Testing - - - - X - - - MCA Test - X X X X - - - X = Yes; L = Late stage faults/Limited detection; - = No

What if you find a problem? Who cares if you find a problem? It’s not like you can fix it yourself… The biggest cost savings in finding a motor fault BEFORE a motor fails (aside from lost production) results in not having to have the motor rewound. Instead of waiting for a motor to fail, why not replace it when it gets “sick”? This allows you to SCHEDULE the motor replacement instead of losing production dealing with UNSCHEDULED down time. Once a motor is shorted to ground (DEAD!) it needs a complete rewind. But, if you can identify DEVELOPING Motor Issues, you can have the motor REPAIRED instead of REWOUND.

What if you find a problem? “Clean, Dip and Bake” vs. Rewind $10, 000 rewind (motor has shorted to ground) OR $3, 000 “Clean, Dip and Bake” (fixing a motor BEFORE shorted to ground) That’s a 70% cost savings over waiting for the motor to fail!

How Do These Instruments Work? 3 -Phase AC Motor example: Both the AT 33 and AT 5 provide clear instructions to walk you through the testing procedure. Then they automatically take the readings and do the calculations. They display the results as “OK” “WARN” or “BAD” (or “No. R” in the case of “no reading”) For more specific information you can highlight each of the categories, hit the “ok” button and display the actual readings across each phase instead of relying on “OK” “WARN” and “BAD”

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

A Single 2 -Minute Test Can Show You: • Shorted windings and developing faults • Poor connections • Winding contamination • Dirt/moisture, burned insulation • Grounded windings • Perform additional tests for rotor, air gap, cables, capacitors, and other components • Or a motor that is electrically healthy

WHAT to Test? What should we test? Uninstalled: A) Spares B) New Motors C) Motors going out for repair D) Motors coming back from repair Installed: A) Motors that have quit running (Troubleshooting) B) Monthly/Quarterly/Annual Inspection (Predictive Maintenance)

ALL-TEST Products © 2014 ALL-TEST Pro, LLC All Rights Reserved

ALL-TEST Pro Instruments (De-Energized) A) Motor Genie B) AT 33 C) AT 5

Trouble Shooting (Motor Genie) Designed to test A/C Induction & some D/C motors Used for: § Incoming Inspection § Trouble-shooting § Combines a Meg. Ohm Meter with a Digital Multi-meter (and throws in a little motor testing) all in one easy-to-use package! § i. Phone/Android app available in June © 2014 ALL-TEST Pro, LLC All Rights Reserved

Trouble Shooting (AT 33) § Incoming Inspection § Designed specifically to test 3 -phase, A/C § Trouble-shooting Induction motors with squirrel-cage rotors ONLY § Pd. M <1000 V (about 90% of all motors) © 2014 ALL-TEST Pro, LLC All Rights Reserved

Trouble Shooting/Pd. M (AT 5) § Designed to test Single & 3 Phase A/C Induction motors (regardless of Voltage or Horsepower), DC and Servo motors as well as Transformers and Generators § Incoming Inspection § Trouble-shooting § Pd. M © 2014 ALL-TEST Pro, LLC All Rights Reserved

ALL-TEST PRO® 5 Features • • Stores 600+ test & reference test records Automatically measures: Resistance; Impedance; Phase Angle; Inductance; I/F; Test Value Static, Stator and Rotor Signatures and Insulation to ground Detects turn to turn & coil to coil faults at early stages Includes *MCA Basic software for download to PC and trending (For 1 & 3 phase AC Motors) *MCA Pro and MCA Pro Enterprise versions also available (For AC, DC, Transformers, Generators, Routing & Work Order generation) Light weight and held: <2 lbs. Non-Destructive, Safe and Easy to Use

MCA PRO Enterprise • Why Enterprise software? – – – Lower software costs for multiple users Engineering can remotely analyze and generate reports Multiple sites may sometimes use the same types of motors but from different vendors. • A shared database allows each site to view individual motor history from other sites and this important information can lead to finding which motor vendors provide the most trouble-free motors.

Energized Testing with Electrical Signature Analysis (ESA) ALL-TEST PRO OL TM (ATPOL II ) § § § ESA Power Quality Sags & Swell Waveform Capture Energy Data Logging

ALL-TEST PRO OL II Advantages • • • ESA, not just MCA Hand-held data collector with wireless control Automated analysis and reporting for AC induction, DC and Synchronous motors. Plus Generators and Transformers Automated Alarms No extra cost for DC motor or motor drive analysisincluded with equipment purchase. Power Quality Analysis

Motor System Diagnostic Technology Comparison PQ Cntrl Conn Cable Stator Rotor Air Gap Ins Brgs Vibe Align Load VFD Off-Line (De-energized) Testing High Pot - - - - X - - - Surge Test - - X - - - - Meg-ohm Meter - - - - X - - - Ohm Meter - - L - - - - PI Testing - - - - X - - - MCA Test - X X X X - - - On-Line (Energized) Testing Vibration - - L L L - X X - Infrared X X X L L - - - L L - Ultrasonics - L - - - X - - L - Volt/Amp L L L - - - - ESA X X L - L X X - X X L X X X L Combined Approach MCA & ESA X X X X

ALL-SAFE PRO

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

ALL-SAFE PRO comes complete with 3 - current transformers (4 CT’s are available as special order)

Why ALL-TEST Pro? Major Advantages: 1) LESS EXPENSIVE than competitive products or unplanned failures 2) FAST perform and save tests in under 2 min vs. 10 -15 min for competitive products 3) SAVE MAINTENANCE $$ by eliminating unscheduled downtime and costly rewinds 4) EASY TO USE - follow on-screen directions (no previous experience necessary) 5) SMALL & LIGHT WEIGHT - less than 2 lbs and hand-held (easy to climb ladders or take into confined spaces) © 2014 ALL-TEST Pro, LLC All Rights Reserved

Why ALL-TEST Pro? Major Advantages (con’t): 5) NON-DESTRUCTIVE – No fear of making a problem worse or blowing up your motor! 6) FIELD PORTABLE - rechargeable batteries mean you can take them anywhere (no outlets or extension cords!) 7) SEPARATE TEST and ANALYSIS FUNCTIONS - perform analysis at your desk while the instrument is back in the field performing tests vs. “all-in-one” configuration 8) FIND DEVELOPING motor issues BEFORE they become failures –schedule maintenance instead of losing valuable production time And Finally…. © 2014 ALL-TEST Pro, LLC All Rights Reserved

Why ALL-TEST Pro? A clear and concise answer as to the electrical health of

Training (Public) • Training – – – 5 -day Regional Seminar for both De-energized & Energized (MCA & ESA*) 3 -day Regional Seminar for De-energized (MCA) portion of course 2. 5 -day Regional Seminar for Energized (ESA)* portion of course * For ESA training attendee must provide own laptop computer.

Training (On-site) • Training* – – – 3 -day On Site for either De-energized (MCA) or Energized (ESA) training for up to 10 people 4 -day On-site combined De-energized (MCA) & Energized (ESA) training for up to 10 people Add 1 -day to On-site training (Add DC motor or transformer analysis to 4 day course) * includes instructor’s travel expenses. (Prices are in USD)

Have questions or need help? Contact Mike Schneider or Tech Support to answer questions A) Mike Schneider = 331 -472 -4029 or mikes@alltestpro. com B) Aaron Schnelle = 414 -375 -9840 or support@alltestpro. com C) Mark Koch (pronounced “Cook”) = 860 -391 -5929 or support@alltestpro. com

ALL-TEST PRO, LLC So, is there another skill you can to learn right now to make you indispensable? Are you tired of putting your job on the line by “guessing” when it comes to motor troubleshooting? Are you tired of using the wrong tools? © 2014 ALL-TEST Pro, LLC All Rights Reserved