MCA Presentation PDF

“Motor Circuit Analysis (MCA™):
Welcome to the 21st Century”

WHO I AM
MIKE SCHNEIDER
REGIONAL SALES MANAGER
MIDWEST
860-391-3877
MIKES@ALLTESTPRO.COM
WWW.ALLTESTPRO.COM
© 2018 ALL-TEST Pro, LLC 2

WHO WE ARE
We make hand-held, field-portable, battery operated
electric motor testing instruments for Motor Circuit
Analysis (MCA™).
These instruments are designed for the end-user to

quickly and easily be able to identify developing
electrical issues within a motor system.
Motor Circuit Analysis (MCA™) is a simple 2-minute test

that will give you a complete picture of your entire motor
system’s electrical health whether used for trouble-
shooting or predictive maintenance.
© 2018 ALL-TEST Pro, LLC 3

WHAT DOES
“FIELD PORTABLE”
REALLY MEAN?
Accessing installed motors:
• In a confined space
• On top of a roof
• At a dryer or oven
• In a pit (submersible)
• May require climbing a stairway
or ladder
• Any outside location
© 2018 ALL-TEST Pro, LLC

ATP MARKETS SERVED
(ALL PRODUCTS)
• Petro-chemical • Pharmaceutical
• Automotive manufacturing • HVAC
• Mining • Water & Waste Water
• Basic metals (steel, aluminum, Treatment
copper, etc.) • Power generation
• Pulp/paper manufacturing • Building maintenance
• Wood products • Food processing
• Cement manufacturing • Aerospace
• High technology manufacturing • Drilling (oil & gas)
• Bottling plants • General manufacturing
• Refining • Logistics

• Marine industry
MOTOR RELIABILITY QUESTIONS

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

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

• What 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?
• Over the course of a typical year, how many
motors do you throw away?
• How many GOOD motors do you throw away?

IMPROVE MOTOR SYSTEM
RELIABILITY BY:
• Testing new motor inventory to

verify condition before installing into
service
• Testing existing motors for
immediate health
• Trending test data for predictive
maintenance practices
• Electrical signature analysis testing
for complete system health

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

hazard due to an unexpected equipment failure

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

and labor utilization

12
IMPACT OF USING DE-ENERGIZED
TESTING FOR MOTOR COMMISSIONING
Some new motors are delivered with defects

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

WHY SHOULD YOU HAVE A MOTOR
TESTING PROGRAM?

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

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

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

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

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

top floor

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

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

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

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

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

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

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

top floor
BASIC MOTOR TESTING

CONSTRUCTION OF A MOTOR
(STATOR)

(STATOR)

(ROTOR)

HOW A MOTOR WORKS

HOW A MOTOR WORKS

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

TO DETERMINE THE REASON
It is that simple!

MOTOR CIRCUIT ANALYSIS (MCA™) BASIC CONCEPT
• MCA™ is a low voltage, sine wave test method

that measures/calculates up to 7 electrical
parameters* and then optionally perform
dissipation factor and insulation to ground tests
• Non-destructive and safe for personnel
performing this de-energized test
*Number of parameters depends upon

MCA™ instrument

MOTOR CIRCUIT ANALYSIS (MCA™)BASIC CONCEPT
In addition to an “Insulation-to-Ground” test, these are the 7
Electrical Parameters being measured:
1. Resistance
2. Impedance
3. Inductance
4. Fi (phase angle)*
5. I/F (current frequency response)*
6. Test Value Static (TVS™)*
7. Dynamic Stator and Rotor Signatures*
This low voltage, sine wave test method is Non-

Destructive and safe for personnel performing this De-
© 2018 ALL-TEST Pro, LLC Energized test.
A change to any of the 7 (or combination of two or more) indicates a different
issue with your motor.
The most important of these is a patented and patent-pending process called
Test Value Static (TVS™)
TVS™ is a sum of the other 6 parameters displayed as a value. This value is

not “good” or “bad” but allows you to do 3 things:
- Compare the motor to itself (if you HAVE a reference test)

- Compare the motor to an identical motor (if you DON’T have a reference test)
- Eliminate false positives caused by rotor position in an installed motor

By noting CHANGES in the TVS™ we can determine if the motor condition is:
-Stable - nothing has changed (value has changed by 3% or less). The

“3%” takes into account possible changes due to changes in temperature or
humidity
-Beginning to deteriorate – something has changed (the value has

changed by 3%-5%). It’s possible that all categories are within our alarm limits
but a combination of small changes can indicate deterioration
-In a near-failure or failure state – something has changed significantly

(the value has changed by 5% or more). Verification that rotor position is
NOT the cause
© 2018 ALL-TEST Pro, LLC of any category readings outside of “alarm” limits
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 MegOhm

Meter and a Multi-meter...
WHY?
REALITY CHECK
Does anyone here:
- Have a Cell Phone?
- Use a Computer?
- Have a Microwave oven?
- Use a GPS?
- Have Cable or Satellite TV?
- Use a TV remote control?

REALITY CHECK
All of these things became available to the consumer in the last

40 years.
All of these things make our lives easier.
All of them are constantly changing AND GETTING BETTER!
The technology behind the Meg-Ohm Meter and Multi-
meter haven’t changed (except to become digital) in more
than 40 years!
Unfortunately, what most folks consider “Motor Testing” is the
exact same thing that was done by our Fathers and
Grandfathers.
REALITY CHECK
These tools were great 40 years ago!

But, so was your 8-Track Tape Player…
And your family vacations in the faux-wood
paneled Station Wagon…
And some of you probably drove a 1978 AMC
Gremlin…
The point is: These were fine products in 1978.
But TODAY there are better ways to listen to
music, better cars and certainly better ways to
test motors!
Let’s talk about a BETTER WAY to do “Motor
Testing”
BASIC MOTOR TESTING
Let’s look at an actual motor test on an installed motor where the drive had
tripped…
The electrician used a

MegOhm Meter and Digital
Multi-meter to acquire these
results.
So, what would you say about

the condition of this motor?

BASIC MOTOR TESTING
Is the problem with the Drive or the Motor?
So, would you replace the VFD or the Motor?
The electrician was relying on a MegOhm Meter (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.
BASIC MOTOR TESTING
Here are the test results again…
Did you replace the

Drive or the Motor?

BASIC MOTOR TESTING
Using Motor Circuit Analysis (MCA™) this is what that same electrician
found…
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 a drive on a different line 10 days later.
Now what? Is it the

Drive or the Motor?

BASIC MOTOR TESTING
Using Motor Circuit Analysis (MCA™) this is what that same electrician
found…
If you said, “Motor” you get a gold star!

BASIC MOTOR TESTING
Using a MegOhm 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 where you 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).
MEGOHM METER & VOLT/OHM METER WHEN USED FOR
ELECTRICAL MOTOR TESTING
* Common electrical testing instruments

**Winding coil faults: turn-to-turn & coil-to-coil
MEGOHM METER & VOLT/OHM METER WHEN USED FOR
ELECTRICAL MOTOR TESTING
**Winding coil faults: turn-to-turn & coil-to-coil

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.
MOST MOTOR FAILURES HAVE A
GESTATION PERIOD
The condition develops over a period of time.

• Once the condition is advanced, it is usually easy
to tell.
• If you have the right tools and knowledge, you can
detect the condition in its early stages.
(i.e.- Before the “blue smoke” is released!)

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

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

MOST MOTOR FAILURES HAVE A
GESTATION PERIOD
Then they develop
“pneumonia”:
A Phase-to-Phase
short Finally, they “Die”:
A Short-to-Ground
Motors start with a

“cold”:
A Turn-to-Turn short Then they get the “flu”:
A Coil-to-Coil short

COMMON MOTOR FAILURES
(ELECTRICAL)
Rotor*
Cracked Rotor Bars
Broken Rotor Bars
Eccentricity (uneven Air Gap between Rotor and Stator)
Contamination (gunk in the Air Gap – grease, cement dust, steel filings, gypsum dust, etc.)
Within the windings*
Turn-to-Turn short
Coil-to-Coil short
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
Causes of Motor Failure
Rotor
Failures
10%
Bearings
Stator 41%
Failures
37%
Balance
and
Alignment
12%

TECHNOLOGY COMPARISON
(DE-ENERGIZED)

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 (has “Died”), 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:
The more advanced instruments

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 “NoR” in the
case of “no reading”)
For more specific information you can

highlight each of the categories, hit
(Virtually any size)* the “ok” button and display the
* Specific to the AT5TM actual readings across each phase
instead of relying on “OK” “WARN”
and “BAD”
WHAT TO TEST?
De-Energized (Off-line) Motor Circuit Analysis (MCA™) for
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)
WHERE TO
TEST
• Motor control center or
disconnect
o Will detect all faults
between test point and
motor winding
o If fault found, go to
equipment
• At winding connections
• Not only detects faults, but
will identify what is NOT
faulty

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

Any voltage motor controller

DE-ENERGIZED
MCA™
CAPABILITIES
• AC/DC motors
• Generators/Alternators
• Machine tool motors
• Servo motors
• AC/DC traction motors
• Control transformers
• Transmission & distribution
transformers
(Virtually any size)*

* Specific to the AT5TM

ALL-TEST PRO TOOLS
De-Energized (Off-line) Motor Circuit Analysis (MCA™) for
• Troubleshooting
• Incoming inspection
• PdM testing (excluding MOTOR GENIE® & AT31TM)
• Accurate and fast motor testing, anytime, anywhere
MOTOR GENIE® ALL-TEST PRO 31TM ALL-TEST PRO 33INDTM ALL-TEST PRO 5TM
WHY MOTOR CIRCUIT ANALYSIS (MCA™)?
MAJOR ADVANTAGES:
1) LESS EXPENSIVE Than unplanned failures

2) FAST – Perform and save tests in under 2 min
3) SAVE MAINTENANCE $$ by eliminating
unscheduled downtime and costly rewinds
4) EASY TO USE – Follow on-screen directions (no
previous experience necessary)
5) SMALL & LIGHTWEIGHT – Less than 2 lbs and
hand-held (easy to climb ladders or take into
confined spaces)

MAJOR ADVANTAGES (con’t):
6) NON_DESTRUCTIVE – No fear of making a
problem worse or blowing up your motor
7) FIELD PORTABLE – Rechargeable batteries mean

you can take them anywhere (no outlets or extension
cords)
8) FIND DEVELOPING Motor issues BEFORE they

become failures – schedule maintenance instead of
losing valuable production time
© 2018 ALL-TEST Pro, LLC AND FINALLY…

9. A CLEAR AND CONCISE ANSWER AS TO THE ELECTRICAL

HEALTH OF YOUR MOTOR IN LESS THAN 2 MINUTES:
AT33
AT5
HAVE QUESTIONS OR NEED HELP?

STOP testing motors like it’s the 1970’s!
Bring your company’s Motor Testing Program into the
21st Century!
Save TIME, MONEY and eliminate HEADACHES by

Investing in Motor Circuit Analysis (MCA™)
QUESTIONS?

ALL-TEST Pro, LLC
PO Box 1139 │ Old Saybrook, CT 06475
Ph: 860.399.4222 │ Fax: 860.399.3180 │ info@alltestpro.com
www.alltestpro.com

MCA Presentation PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MCA Presentation PDF

Uploaded by

Copyright:

Available Formats

“Motor Circuit Analysis (MCA™):

Welcome to the 21st Century”

© 2018 ALL-TEST Pro, LLC 2

These instruments are designed for the end-user to

Motor Circuit Analysis (MCA™) is a simple 2-minute test

© 2018 ALL-TEST Pro, LLC 3

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

• Testing new motor inventory to

© 2018 ALL-TEST Pro, LLC

Costs must include lost production and labor utilization

Do not overlook the costs associated with an environmental

© 2018 ALL-TEST Pro, LLC

Industry Avg Cost Per Hour*

Forest Products $7,000

Food Processing $30,000

Metal Casting $100,000

Costs must include lost production

© 2018 ALL-TEST Pro, LLC

Some new motors are delivered with defects

Can recoup investment with a single “find”

Also applies to repaired and spare motors

Do you know the status of your spares?

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

Payback on the initial investment can

Driving results, from the shop floor to the

© 2018 ALL-TEST Pro, LLC

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

Increased Annual Energy Costs = $776.16

Hours saved in Finds “good” Eliminates wasted

© 2018 ALL-TEST Pro, LLC

Prevent start up failure Get system running

EITHER WILL EASILY COST JUSTIFY A MOTOR TESTING PROGRAM

Plus – we have not included using for:

Driving results, from the shop floor to the

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

© 2018 ALL-TEST Pro, LLC

Each “phase” is made up of the same gauge wire, the same

Using Motor Circuit Analysis (MCA™) we compare the

ALL BALANCED ONE OR MORE UNBALANCED

GOOD NOT GOOD

LOOK AT AND COMPARE MULTIPLE MEASUREMENT PARAMETERS

© 2018 ALL-TEST Pro, LLC

• MCA™ is a low voltage, sine wave test method

*Number of parameters depends upon

© 2018 ALL-TEST Pro, LLC

This low voltage, sine wave test method is Non-

TVS™ is a sum of the other 6 parameters displayed as a value. This value is

- Compare the motor to itself (if you HAVE a reference test)

© 2018 ALL-TEST Pro, LLC

-Stable - nothing has changed (value has changed by 3% or less). The

-Beginning to deteriorate – something has changed (the value has