ALL-TEST PRO 7 Instrument User Manual

Mca tester and analyzer for electrical motors, generators and transformers

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ALL-TEST PRO 7™ (AT7™)

ALL-TEST PRO 7™ PROFESSIONAL

(AT7P)

Instrument User Manual

Version 1.0

MCA

Tester and Analyzer for Electrical Motors, Generators and

Transformers

REV 06/20/2019

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Summary of Contents for ALL-TEST PRO 7

Page 1 ALL-TEST PRO 7™ (AT7™) ALL-TEST PRO 7™ PROFESSIONAL (AT7P) Instrument User Manual Version 1.0 Tester and Analyzer for Electrical Motors, Generators and Transformers ©2019 ALL-TEST Pro, LLC All Rights Reserved REV 06/20/2019...
Page 3 Contact Information ..........................5 SAFETY ................................6 SAFETY WARNINGS ........................6 Introduction .............................. 6 Safety Symbols ............................7 ALL-TEST PRO 7™ SERIES TEST KIT ........................ 8 Test Lead Connections ..........................8 Instrument Layout............................. 9 Input/Output Ports ..........................9 Battery Charging Port ..........................9 Front Panel Layout ..........................
Page 4 1 - Phase AC Test ............................. 38 Rotor Test ..............................40 Rotor Test steps ..........................41 DC MOTOR TEST ............................42 New or Rebuilt Motors (Baseline Testing) ....................42 Used Motors (Trending) .......................... 43 ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 5 Individual Coil Testing ..........................54 ROUTE ................................. 55 Route Operation ............................. 55 COMMUNICATION ............................57 ALL-TEST PRO Instrument Communications Set-up ................57 SETUP ................................58 VIEW/DELETE Record ..........................58 Viewing Saved Test Data ........................58 Exiting Test Records Screen ........................ 59 Deleting Test Records .........................
Page 6 Experience has proven that the ALL-TEST PRO® series of MCA instruments are the most powerful and easiest to use diagnostic tools available for deenergized testing of motors in today’s industry.
Page 7 ALL-TEST PRO 7™ User Manual Warranty One-year limited warranty. See ALL-TEST Pro Terms and Conditions for details. Contact Information ALL-TEST Pro, LLC PO Box 1139 Old Saybrook CT 06475 Phone: 1.860.399.4222 Email: support@alltestpro.com Web: www.alltestpro.com ©2019 ALL-TEST Pro, LLC All Rights Reserved...
Page 8 (disconnect electronic equipment) when performing the insulation to ground resistance test (Meg-Ohm test). Test leads including crocodile clips must be in good shape, clean and have no broken or cracked insulation. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 10 ALL-TEST PRO 7™ User Manual ALL-TEST PRO 7™ SERIES TEST KIT • 3x Test Leads with heavy duty Kelvin Clips and push-pull connectors • 1x Test Lead with 4mm safety plug and MC “Dolphin” clip • Charging adapter, Universal input type 100-240VAC, output 9VDC @ 1.7A...
Page 11 Only use the supplied charger for charging. Using different charger could damage your instrument and void the warranty. It is recommended to leave the instrument plugged into charger SIDE VIEW when not in use. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 12 Status indicator LED ❾ 15 Key Input pad area, backlit sealed ❿ tactile switches Rear View ALL-TEST PRO 7 series manufacturers ⓫ nameplate and identity tag Lithium Ion Battery Pack ⓬ ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 13 ALL-TEST PRO 7™ User Manual MAIN MENU The main menu provides the icons to access the various tests and other functions of the ALL-TEST PRO 7™ instruments. The LCD display provides the screens, instructions and displays necessary to perform deenergized tests on: •...
Page 14 DC – Performs deenergized winding tests and insulation to ground tests on various types of DC motors. *DC motors and coil test only available with ALL-TEST PRO 7 PROFESSIONAL. Two test options. "1-Phase" test accesses DF and capacitance of winding to ground, insulation resistance to ground and other physical quantities on any single-phase motor.
Page 15 The battery typically takes 2.5 hours to fully charge. Charging status is indicated by bi-color LED to the left of keyboard: = Battery conditioning and charging Green = Charge complete OFF = Charger not connected ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 17 Now the instrument can be turned on normally. Turning the instrument OFF Select the "PWR OFF" icon ❷ in the main menu with the arrow keys and then press "OK" ❸ key as shown below. ❷ ❶ ❸ ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 19 INS – “IND” means insulation resistance to ground test and is part of the “IND” test and “Z/” test. This menu provides a convenient direct access for insulation test. Before going into the details on how to perform the test, the general testing theory is presented first below. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 20 For over 30 years the ALL-TEST PRO® line of motor testers have been the leaders in the industry in providing easy-to-use handheld instruments specifically designed to test motors. It injects a series of low voltage signals into the winding system to exercise the effects of the conductors as well, as the interaction with the insulation system.
Page 21 The static tests refer to the deenergized motor winding tests performed with the motor rotor in a stationary “static” position. It uses ALL-TEST Pro’s proven testing methods to measure the windings in all three phases at various pre-determined test frequencies. The results of these tests are used to calculate the patented Test Value Static (TVS) and Reference Test Value Static (REF TVS) (REF TVS).
Page 22 (typically 40° C) so that trends and changes in insulation resistance can be readily detected. Contamination, humidity, temperature, and other factors affect insulation resistance values. The standard recommends choosing test voltages for insulation resistance testing: ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 23 Dynamic tests need to be performed directly at the motor. Testing from the starter or motor drive can introduce external sources of interference that can adversely influence the test results. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 24 If values have changed from initial static test, then the user will need to perform a complete DF/C + Insulation + Static + Dynamic to determine the root cause for this change. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 25 To start the static and dynamic tests, select the “IND” icon in the Main Menu and press the OK key. DF/C Test Connect the test leads according to instructions in the message screen. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 26 After the DF and Capacitance test is complete then the display will show the measured values. Press “OK to continue… or MENU to remeasure…” Insulation Resistance Test (MΩ) Next step is the selection of “Insulation Test?” Select “NO” or “YES” and press OK. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 27 TEST ˅key until a value very close to 0 is displayed. If any other value is displayed one or the other of the test leads are not properly connected to ground. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 28 NOTE: If “No Connection” is detected by the instrument it will display the warning message listed above. If your connection to the motor is correct, then you can force it to sequence to the next phase by pressing OK. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 29 “beep” tone to help the user turn the shaft at the proper speed. 4 beeps per revolution = 15 RPM. 8 beeps per revolution = 7.5 RPM. We suggest using a “shaft strap” as shown in this picture.
Page 30 Maximum recommended rotor shaft rotational speed for 2 & 4-pole motors = 15 RPM Maximum recommended rotor shaft rotational speed for 6-pole motors or higher = 7.5 RPM Viewing Results Upon Test Completion After the STATIC and DYNAMIC tests are done, the instrument will automatically analyze, calculate and display the result menu screen, reporting OK, WARN, BAD or NoR = No Reading.
Page 31 OK key is pressed to select “Stator” on the left screen. The Stator submenu will display the “Test Signature Pattern” if a DYNAMIC test was done. If only STATIC tests were done, then the TVS=“Test Value Static” (dimensionless) will be displayed. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 33 Momentarily pausing after a key stroke will cause the curser to automatically move to the next blank space. And the new or different Alpha character can now be entered in that space. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 34 REF is the option to choose. You will go through the same saving steps for either option. The only difference between SAVE and SAVE as REF is the type of data saved in the instrument ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 35 Motor/ID/Ser#: Unique ID for the motor; Each motor should have its own ID that remains with the motor; Any combination of alpha-numeric characters or underscores, maximum 18 characters NEXT skips this menu and goes to next menu. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 36 COMPARE to REF Press the key. This will display the Find REF: screen: 5. Select Browse saved REF:s 6. Press the key. The instruments will display REF: Location Motor ID/Ser.# Motor Type ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 37 Highlight , then the screen returns to the main menu REMEASURE The user also has the option to do the same measurements again from the beginning by pressing “REMEASURE”. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 38 When open the Z/ menu, there are three that can be selected: Motor, Transformer, or Motor Rotor COMP. *Transformer test only available in ALL-TEST PRO 7 PROFFESIONAL. The operation steps are the same for Motor and Transformer and the displayed results are also similar, however, the transformer adopts a different alarm analysis algorithm from motor based on characteristics of transformer windings.
Page 39 Run MCA software to upload the test data and perform the 3 Phase AC individual analysis. If no WARN or BAD alarm shows up on the parameters of impedance, inductance, phase angle and I/F, it means the motor is in good condition. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 40 “Rotor Test” is used for diagnosing problems with rotor after the stator is determined to be good. 1 - Phase AC Test 1. 1-Phase AC test starts with DF/C test as shown below. 2. Choose to perform insulation test. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 41 MCA software manual for the analysis performed in MCA software. 6. For the operations to save the test, exit or remeasure, refer to the Section “Test Save and Reference Comparison” in Chapter “ind/dyn/ins – ac INDuction motor test”. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 42 Rotor test is only performed on 3 Phase AC motor after stator is determined to be fault-free. For motors with pole number 4 or less, 48 tests at minimum have to be performed on 48 different positions for one cycle. In other words, one test has to be performed every 7.5 around 360 .
Page 43 To change frequency, choose “fHz”, highlight the desired frequency, then press “OK” key. c. When all rotor tests are completed, choose “EXIT”. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 44 The motor tests made with the AT7 PROFESSIONAL are done with all of the motor windings connected. If a change is identified, then it is necessary to individually test the coils to identify the faulty coil. More detailed analysis procedures are available in the ALL-TEST Pro MCA analysis manual.
Page 45 If a change has occurred, disconnect the motor and test at the motor directly. Compare the current motor data taken directly at the motor to the baseline average data set previously taken directly at the motor for those machines. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 46 If a change in the motors condition is “detected” during the motor drive test it is then recommended to perform the test directly at the motor. The following is a list of configurations for tests from DC drive. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 47 INS1 = field windings to ground INS2 = armature windings to ground INS3 = field winding to armature winding STATIC readings for DC Compound Single Voltage Motors DC1 = Field Coils ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 48 INS2 = armature windings to ground INS3 = field winding to armature winding STATIC readings for DC Shunt Dual Voltage Motors DC1 = Field Coil 1 DC2 = Field Coil 2 DC3 = Armature Coil ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 49 INS2 = armature windings to ground INS3 = field winding to armature winding STATIC readings for DC Compound Single Voltage Motors DC1 = Series & Armature Coil DC2 = Field Coil ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 50 INS3 = field winding to armature winding STATIC readings for DC Shunt Dual Voltage Motors DC1 = Series & Armature Coil DC2 = Field Coil 1 DC3 = Field Coil 2 ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 51 Additionally, it is also possible to take IRG measurements on the individual field and armature windings. INS1 = field windings to ground INS2 = armature windings to ground STATIC readings for DC Series Motors DC1 = Series Field Coil DC2 = Armature Coil ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 52 INS1 = field windings to ground INS2 = armature windings to ground INS3 = field winding to armature winding STATIC readings for DC Compound Single Voltage Motors DC1 =Shunt Field Coil DC2 Armature Coils ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 53 INS2 = armature windings to ground INS3 = field winding to armature winding STATIC readings for DC Shunt Dual Voltage Motors DC1 = Field Coil 1 DC2 = Field Coil 2 DC3 = Armature Coil ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 54 INS2 = armature windings to ground INS3 = field winding to armature winding STATIC readings for DC Compound Single Voltage Motors DC1 =Series DC2 = Shunt Field1 Coil DC3 = Armature Coil ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 55 INS3 = field winding to armature winding STATIC readings for DC Shunt Dual Voltage Motors DC1 = Series coil DC2 = Field Coil 1 DC3 = Field Coil 2 DC4 = Armature Coil ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 56 This is required for trending purpose in MCA PRO software, which essentially compare coils in different groups instead of trending over time. For coil individual analysis, this is not required. Please refer to MCA software manual for details. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 57 Upload all test data before route downloading. 2. From the main screen highlight the icon. 3. Press the key to access the Route Screen. 4. Three options available: ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 58 1 one to be available. 7. If “TEST” is chosen, the following menu shows up so that the users can choose the type of test desired Note: the transformer test is included in the 2nd test listed 8.
Page 59 Key to place the instrument in the communications mode, the screen will display: Now the instrument is set in communication mode. For communication operations, please check the MCA software user manual. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 60 This displays the REC #, and identifies the Motor data test as a TEST or REF data set. • Time: Time the Motor Test was performed • Date: Date the Motor Test was performed • Type: Type of Motor data set ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 61 VIEW/DELETE Test Records Display screen To delete another test record repeat steps 5,6,& 7 From the VIEW/DELETE Test Records Display screen Highlight CANCEL...
Page 62 <; > keys to move another selection. Repeat steps 6, 7 & 8, until correct date and time are set. 10. Press key when current Date/Time is set, this will return the display to the Main Menu.
Page 63 On the bottom of the “SET” menu, the instrument firmware version is displayed. For the example below, the version number is “AT7P190610D”. Note: Whenever a problem is reported to tech support, always include the firmware version number in the communication. ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 64 1 – 200mH ±2%, all other values ±3% Relative Accuracy “Phase to Phase” ± 0.2% Phase Angle ϕ 1– 90° ±1°, Max Resolution: 0.1° Relative Accuracy “Phase to Phase” ± 0.1° ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 65 Temperature Range (Storage) -20 °C to +55 °C (-4 °F to +131 °F) Temperature Range (Operating) -10 °C to +50 °C (-4 °F to +122 °F) Humidity 0-80% relative humidity, non-condensing ©2019 ALL-TEST Pro, LLC All Rights Reserved Rev 06/20/2019...
Page 66 Charging adapter, Universal input type 100 - 240VAC, output 9VDC @ 1.7A Refer to software specification sheet ALL-TEST PRO 7™ - MCA Basic™ Software ALL-TEST PRO 7™ PROFESSIONAL - MCA PRO™ Software 1x USB cable 1m Durable and rugged hard case with pre-cut foam liner...
Page 67 Marks without the written permission of ALL-TEST Pro, LLC. Any misuse of the Marks or any Content, except as provided in this Statement, is strictly prohibited and may violate trademark laws.
Page 68 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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