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Related Manuals for ALL-TEST PRO Motor Genie MCA
Summary of Contents for ALL-TEST PRO Motor Genie MCA
- Page 1 Motor Genie MCA™ User Guide Product # 50102 (English) Rev. January 15, 2024 (English) Specifications are subject to change without notice. All product names are trademarks of ALL-TEST Pro. ©2024 ALL-TEST Pro. All Rights Reserved.
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Page 2: Table Of Contents
Motor Genie MCA User Guide Table of Contents Table of Contents ..............................2 Quickstart Guide ..............................4 1. Introduction ..............................6 2. Safety Warnings and Precautions ........................7 3. Standard Equipment & Warranty ........................9 3.1 Equipment Contents ............................... 9 3.2 Warranty................................... - Page 3 Motor Genie MCA User Guide 8. Typical Motor Testing Procedures ......................... 30 8.1 Resistance Test Instructions ..........................31 8.2 Insulation Test Instructions ..........................32 8.3 Motor Genie Test Instructions ..........................35 8.3.1 Realtime Values .............................. 36 8.4 Rotor Compensated Test Instructions (MAX Z) ....................37 8.5 Cable Testing Instructions ...........................
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Page 4: Quickstart Guide
Motor Genie MCA User Guide Quickstart Guide... - Page 5 Motor Genie MCA User Guide...
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Page 6: Introduction
1. Introduction Dear Customer, Thank you for your purchase of the new, patented MOTOR GENIE MCA™ (MG MCA™) motor circuit analyzer from ALL-TEST Pro, LLC ® (ATP). The MOTOR GENIE MCA™ has been developed to provide simple and accurate test methods for troubleshooting faults, commissioning new and rebuilt machines, and verifying quality assurance in electric motors. -
Page 7: Safety Warnings And Precautions
Personal Protective Equipment (PPE). Improper or unsafe operation of the ALL-TEST PRO MG MCA™ is the sole responsibility of the user. Do not open the main body of the instrument. Opening the instrument body will void the warranty. There are NO serviceable parts inside. - Page 8 The ALL-TEST PRO MG MCA™ sends out a series of low voltage, high frequency AC and DC test signals to the motor to exercise the winding insulation system. These voltages are not harmful to the technician or most electronic equipment (variable frequency drives, encoders, soft starters, etc.).
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Page 9: Standard Equipment & Warranty
Please download the MOTOR GENIE APP available for free for IOS/Android. 3.2 Warranty One-year limited warranty from date of purchase included. See ALL-TEST Pro Terms and Conditions for details. 3.3 Accessories The following accessories are currently available for purchase at alltestpro.com or your equipment supplier: 1. -
Page 10: Instrument Features
Motor Genie MCA User Guide 4. Instrument Features 4.1 Exterior 4.1.1 Front Panel 1. Graphical LCD display 128x64, white LED backlight 2. Charging status indicator LED, bicolor Red / Green 3. Active status indicator LED YELLOW 4. Keypad area sealed tactile switches. Press ↓... -
Page 11: Batteries And Charger
Motor Genie MCA User Guide 4.2 Batteries and Charger The built-in rechargeable Lithium (Li-ION) batteries support eight hours or more of normal testing. 2.5 hours of charging is typically necessary to fully charge the battery. Do not charge when ambient temperature is below or above range as listed in the specifications (see page 11 for more details). -
Page 12: Temporary Memory
Motor Genie MCA User Guide 25Hz 50Hz 100Hz 200Hz 400Hz 800Hz Ψ Switch to 25Hz/50Hz 50Hz/100Hz 100Hz/200Hz 200Hz/400Hz 400Hz/800Hz 400Hz NOTE: It is possible that the above guidelines of NOTE: Induction motors are electrically like identifying developing winding faults can be provide transformers with a rotating secondary. -
Page 13: Specifications
Motor Genie MCA User Guide 4.5 Specifications Test Frequencies: 50, 100, 200, 400, 800 Hz Motor Genie Test: Repeatability ±1%, (of measured data and calculated deviations) Resistance: True 4-wire Kelvin measurement. Compensation for thermoelectric offset voltages. Measurement range: 0.1 mΩ – 999 Ω... -
Page 14: Operation Instructions
Motor Genie MCA User Guide 5. Operation Instructions 5.1 Basic Functions Key Functions NOTE: Instrument keys may have additional functionalities in certain modes. (1) MENU / UP Arrow Return to Main Menu from different modes Moving UP selection field on vertical menu... - Page 15 Motor Genie MCA User Guide Turning the Instrument OFF There are 3 ways how to turn the instrument OFF: Normal, Automatic, and Hardware Off. Normal key to select (highlight) the icon PWR OFF, then press Automatic The instrument will automatically turn OFF after 5 minutes of inactivity.
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Page 16: Main Menu
Motor Genie MCA User Guide 5.2 Main Menu The MAIN MENU screen has three sections: (1) Function Selection Area (2) Date and Time display in YYYY-MM-DD / HH:MM:SS format (3) Battery Charge Status Indicator will show one out of four battery charge levels and LOW. -
Page 17: Testing Functions
Motor Genie MCA User Guide 5.3 Testing Functions 5.3.1 Resistance Test Select the resistance icon from main menu press button - instrument will display the test leads connection information. Follow the onscreen instructions to connect the test leads. and press button to start the measurement process. -
Page 18: Insulation Test
Motor Genie MCA User Guide 5.3.2 Insulation Test Insulation Resistance: 0MΩ – 5GΩ @1000V/@500V WARNING: Risk of electric shock! Pressing the TEST key will output the selected test voltage of 500V or 1000V to the yellow output port and illuminate orange status LED. -
Page 19: Motor Genie Test
Motor Genie MCA User Guide 5.3.3 Motor Genie Test The Motor Genie Test measures and displays a real time value of Impedance(Z), or Current Frequency Response (I/F), or Phase Angle (ψ) for each of three phases under the operator control. - Page 20 Motor Genie MCA User Guide ⑤ Measurement Type Pressing the key sequentially changes the measurement type from (Z) to (I/F), from (I/F) to (ψ), and from (ψ) back to (Z). NOTE: The current displayed Measurement Value will be stored in the Temporary Test...
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Page 21: Setup Menu
Motor Genie MCA User Guide 5.4 Setup Menu Select required command from the Setup Mode Menu list using keys then press VIEW Test Records Recall and review Tests Stored in the data memory. SET Date/Time Set/correct the real time clock date and time. -
Page 22: View Test Records
Motor Genie MCA User Guide 5.4.1 View Test Records (Main Menu > SET > VIEW Test Records) Select one of seven memories to view the test data using & keys then press NOTE: The lower part of the display screen shows the Date and Time for the selected stored test. -
Page 23: Manual Test Operation
Motor Genie MCA User Guide 5.4.3 Manual Test Operation (Main Menu > SET > Manual Test) The Manual test performs individual Measurements of R, ψ, I/F, Z using just two test leads. 1. Select Leads. Select which test leads are being used for the test moving highlighted selection using &... -
Page 24: Calibration
Motor Genie MCA User Guide (R) Resistance Manual measurement result screen displays the resistance value in Ohms or milliohms. This value will also be stored in the Temporary Test Memory for the corresponding phase. (ψ) Phase Angle manual measurement result screen displays four measurements done at 50Hz, 100Hz, 200Hz, and 400Hz frequencies. -
Page 25: Measurement Screen Controls
Motor Genie MCA User Guide 5.5 Measurement Screen Controls At any point during testing the Measurement type, Connected Phase or Test Frequency can be changed. To change the Measurement type Press to switch between Impedance (Z), Current Frequency Response (I/F), and Phase Angle (ψ) measurement. - Page 26 Motor Genie MCA User Guide I/F – Current Frequency response in percent for each phase and calculated difference between the phases and a set of Frequencies used for the I/F test. PB – Phase Balance calculated as a difference between MaxZ Impedance for each phase (use for the Rotor Compensated test only).
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Page 27: Good, Warn, Bad Analysis Measurement Guide
Motor Genie MCA User Guide 6. Good, Warn, Bad Analysis Measurement Guide The MOTOR TEST Result Screen displays the values of the measured variables and compares them to predetermined guidelines and provides results in 3 alarm levels (OK/WARN/BAD or NoR). -
Page 28: Collecting The Complete Set Of Motor Test Data
Motor Genie MCA User Guide 7. Collecting the Complete Set of Motor Test Data Run the Resistance Test to collect the phase Resistance Values. Perform the Insulation Test to collect the Insulation Resistance Value. Start the MOTOR GENIE real time test and collect all data by switching between all 3 phases (T1-T2-T3) and taking every measurement (Impedance, I/F, and Phase Angle) for each phase. - Page 29 Motor Genie MCA User Guide Complete data collection: Finish the measurement process pressing any time (after all values for all 3 phases are collected). This will save the latest value to Temporary Test Memory, stops the real time measurement, and display the test result screen.
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Page 30: Typical Motor Testing Procedures
Motor Genie MCA User Guide 8. Typical Motor Testing Procedures These are the recommended tests to evaluate the condition of a typical three-phase squirrel cage motor: 1. ALL TEST PRO MCA Tools required that the Motor MUST be Fully DEENERGIZED. Put the Main Switch into the OFF position or use any other available method to disconnect the Power from the Motor. -
Page 31: Resistance Test Instructions
Motor Genie MCA User Guide 8.1 Resistance Test Instructions The resistance deviations of less than 3% show the good coil symmetry and a contact quality. Connect all three test leads to the motor ①❷❸ and push the [OK] button. Increased deviations in resistance can be caused by... -
Page 32: Insulation Test Instructions
Motor Genie MCA User Guide Resistance Resistance Status Definition Deviation Status < 3 % Good motor (Good cable and connections) WARN Resistance deviation is higher than normal. That may affect the longevity of the motor causing contact overheating, energy loss, ≥... - Page 33 Motor Genie MCA User Guide Best electrical practices require verifying that the yellow ground lead is properly connected to ground or machine frame. To verify the proper connection: • Connect the yellow test lead to the motor frame or ground, then connect the blue lead to the machine frame at a different point or location.
- Page 34 Motor Genie MCA User Guide Insulation Resistance Values (IEEE 43-2013) Application Pass/Fail Value Insulation systems prior to 1970 > 1 Meg-Ohm + 1 Meg-Ohm per kV rating of motor Random Wound motors less than 600 V > 5 Meg-Ohms MG MCA defines the Ground Wall Insulation status as shown on the table below:...
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Page 35: Motor Genie Test Instructions
Current Frequency Response (I/F), Phase Angle (ψ). It is designed to provide early indications of developing the winding’s insulation faults indicating OK/WAR/BAD status on the result screen. During testing, Motor Genie MCA applies a low and should be considered “invalid”. The cause of voltage AC sinusoidal signal at the selected significant fluctuation should be investigated. -
Page 36: Realtime Values
Motor Genie MCA User Guide 8.3.1 Realtime Values (Z) Impedance is a measure of the opposition to Unbalances of the (I/F) in any of the phases which electrical flow. It is measured in ohms. For Direct are > 2% from the average provide early indication of Current (DC) systems, Impedance(Z) and a developing winding short. -
Page 37: Rotor Compensated Test Instructions (Max Z)
Motor Genie MCA User Guide 8.4 Rotor Compensated Test Instructions (MAX Z) 1. Perform the Resistance Test and the Insulation Test to collect values into the Temporary Memory or clear the previous Resistance and Insulation test data by pressing &... -
Page 38: Cable Testing Instructions
Motor Genie MCA User Guide 8.5 Cable Testing Instructions 1. Attach the test leads to one end of the cable. Twist, wind, or tie the opposite cable ends together and perform the R resistance test. 2. Connect the Black lead to one of the cables, the blue to another, and the red lead to the third cable. -
Page 39: Manual Test Mode
Motor Genie MCA User Guide 9. Manual Test Mode The manual mode is located in the SET ICON. Manual Test Mode is used to individually test the R, ψ, I/F or Z of coils or windings in motors and also other electrical machinery or components, such as conductors, insulators, resistors, switches &... -
Page 40: Condition Calculator App
Motor Genie MCA User Guide 10. Condition Calculator App The ALL-TEST Pro Motor Genie app is available for download to your mobile phone for Android® and Apple®. Using the App Step 1: Press top button that says “add New Test”... -
Page 41: Mapping Test Data To The App
Motor Genie MCA User Guide 10.1 Mapping Test Data to the App ALL-TEST PRO MOTOR GENIE application available for download for Android® and Apple® devices. -
Page 42: Troubleshooting
Motor Genie MCA User Guide 11. Troubleshooting Charging If the unit does not fully charge, the batteries fell below the minimum charge. The first charge will bring the batteries back to the minimum level. To generate a full charge, disconnect the instrument from DC charger, then reconnect the instrument and start a new charge that will bring the instrument charge to the full status. -
Page 43: Glossary
ALL-TEST Pro, LLC in the United States and certain other countries throughout the world. Nothing contained in this manual should be construed as granting, by implication, estoppels or otherwise, any license or right to use any of the Marks without the written permission of ALL-TEST Pro, LLC. - Page 44 Nothing contained herein shall be construed as conferring by implication or otherwise any license or right under any patent or trademark of ALL-TEST Pro, LLC or any third party. No other rights under any copyrights of ALL-TEST Pro, LLC or any other party are granted herein, except as expressly stated above.
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