MotorAnalyzer Manual PDF

SCHLEICH
TECHNOLOGY IN ADVANCE

MotorAnalyzer

Operating Manual
Schleich GmbH | D-58675 Hemer | An der Schleuse 11 | 0049 (0)2372 94980 | info@schleich.com - Never operate the device at motors under voltage! - 2

Index

1 Introduction ............................................................................................................................................................... 4
1.1 Range of application ................................................................................................................................................................. 4
1.2 Liability................................................................................................................................................................................... 4
1.3 Copyright ................................................................................................................................................................................ 4
2 Switching on the MotorAnalyzer and the charging device........................................................................................... 5
3 Front view, operating elements and connections........................................................................................................ 7
3.1 Function buttons S1...S4 ............................................................................................................................................................ 8
3.2 Graphic symbols on the display ................................................................................................................................................... 8
4.1 Auto. Test: automatic analysis at a 3-phase stator (without reference) .................................................................. 9
4.2 Auto. Test: automatic analysis at a stator (with reference)................................................................................... 10
5.1 Surge test: Stator or coil test with comparison between the individual phases .............................................................. 11
5.2 Surge test: Armature test, field test or testing of individual coils ................................................................................. 13
5.3 Surge test: Stator or coil test with phase comparison to a reference stator ................................................................... 14
5.4 Surge test: 3-phase motor test with phase comparison between the 3 phases............................................................... 17
6.1 Resistance test: Stator or coil test with or without set values ..................................................................................... 18
6.2 Resistance test: PTC thermistor detector test............................................................................................................ 21
6.3 Resistance test: Armature, field or single coil test ..................................................................................................... 22
7 High voltage test ...................................................................................................................................................... 24
8 PI/DAR test : (PI) Polarization index / (DAR) dielectric absorption relation................................................................... 27
9 Insulation resistance test......................................................................................................................................... 29
10 PE test .................................................................................................................................................................... 31
11 Neutral zone adjustment..................................................................................................................................... 32
12.1 Sense of rotation test at stators .......................................................................................................................... 33
12.2 Sense of rotation test at motors .......................................................................................................................... 34
13 Field strength test .................................................................................................................................................. 35
14.1 Inductivity test - turn-to-turn test: at stators......................................................................................................... 36
14.2 Inductivity test - turn-to-turn test: at armatures .................................................................................................... 37
15 SetUp...................................................................................................................................................................... 38
16 Operation of the SetUp / changing values and settings.......................................................................................... 39
17 Remote control ....................................................................................................................................................... 40
18 PC program PrintCom.......................................................................................................................................... 41
18.1 PrintCom under EXCEL97...................................................................................................................................................... 44
19 Bootloader / updating the tester with a new program ........................................................................................... 45
19.1 General information on the Bootloader...................................................................................................................................... 45
19.2 Programming ........................................................................................................................................................................ 46
19.3 Connection cable between tester and PC................................................................................................................................... 48
20 Glossary ................................................................................................................................................................. 49
20.1 Connection board assignment at 3-phase motors ....................................................................................................................... 49
20.2 Ambient temperature compensation at resistance test ................................................................................................................ 50
20.3 Test time for the resistance test at inductances.......................................................................................................................... 51
20.4 Test current table / resistance test ........................................................................................................................................... 51
20.5 Accuracy at resistance test...................................................................................................................................................... 52
20.6 4-wire resistance measurement at resistance test ...................................................................................................................... 53
20.7 Resistance test at armatures ................................................................................................................................................... 56
20.8 Surge test ............................................................................................................................................................................ 57
20.9 Explanation on the interpretation of results at surge tests ........................................................................................................... 62
20.10 Surge test for detecting a twisted phase.................................................................................................................................. 64
20.11 Insulation resistance test and PI ............................................................................................................................................ 65
20.12 Explanations on the high voltage test...................................................................................................................................... 66
21 Digital high voltage tester GLP1e-HV or high-voltage tester with analog display GLP1a-HV .................................. 69
1 Introduction

1.1 Range of application

The MotorAnalyzer serves for testing electric machines and drives.

The MotorAnalyzer is to be used for testing off-load test objects only. When the MotorAnalyzer is connected or during the test, no mains voltage must be
connected to the motor.
Any usage other than this is regarded as not appropriate.
For any damage resulting from inappropriate usage, the manufacturer/supplier cannot be hold liable; the user bears all risks.
Before the device is switched on for the first time or after it has been transported, it needs to adapt to the ambient temperature first. Please unpack the device
and put it on a table. You should wait at least 30 minutes before switching it on.

The device must not be exposed to the condensation of water.

We are pointing out that it is necessary to calibrate and, if necessary, adjust the testing device annually and after every modification (repair), which can
influence the measuring hardware. The manufacturer usually tests the device for its accuracy and the calibration is certified with a protocol.

For test methods, measure ranges and accuracies please refer to the enclosed calibration protocol.

1.2 Liability

The testing device has been designed according to the latest developments in technology, it is tested and is therefore operationally reliable. In case the tester is maintained or repaired improperly by
persons not authorized by Schleich GmbH, the liability will in any case be passed on to the owner. The same applies if the testing device is operated in any other way than described in this manual.
(See chapter Range of application).

The user is obliged to operate only testers that are in perfect condition.
Messrs. Schleich GmbH is liable for mistakes and omissions, with the exception of further claims, only within the framework of the guarantee commitments in the order confirmation (respectively the
commitments in the offer).

In view of the permanent development and improvement of our products, we reserve the right for technical modifications at any time. Such modifications, mistakes and misprints do not imply a claim
for damages.

Furthermore, only original Schleich GmbH spare parts and accessories may be used. For any damage arising from non-observance of the instructions in this operating manual, Messrs Schleich GmbH
does not accept liability. Only the German original of this operating manual is binding. The above information does not extend the liability- and guarantee agreements of the conditions of sale and
delivery of Messrs. Schleich GmbH.

1.3 Copyright

Messrs. Schleich GmbH holds the copyright for this operating manual. This operating manual has been written for the operating and supervising personnel of the tester. It contains instructions and
technical illustrations that may neither completely nor partly be copied, distributed or used for competition purposes or given to a third party.
2 Switching on the MotorAnalyzer and the charging device

The MotorAnalyzer can be switched on at the back panel. After switching on, the MotorAnalyzers shows the following display:

The version number of the software and the serial number (project number) of the MotorAnalyzer are indicated.

While testing, no mains voltage of the motor to be tested must be connected to the tester.

Please make sure that the motor can not be switched on. If possible, disconnect the motor.

To confirm that the motor must be voltage-free, please activate the S2 button okay.

After switching on, the tester indicates the charge of battery. The battery symbol should always indicate full.
If the battery symbol is empty, the voltage has fallen below 11V. Now, the charging device must be connected. Otherwise, the battery could discharge too much and thus be
destroyed.

The battery symbol is also indicated during the test. If the voltage falls below 11V, the battery is damaged and the test results can become
faulty.


Only when the charging device is connected, the high voltage source delivers the full output voltage. The more the battery is empty, the lower is the output voltage. The indicated voltage and
the flowing current remain correct, though.

If the voltage of the battery falls below 11V, the background lighting of the display will switch off in order to save energy.

The charging device can always be connected. Even if the MotorAnalyzer is switched off, the battery will charged. When the charging device is connected, this will be indicated by the red LED
at the charging device. The green 12V LED should be on, also.

If the 6V LED at the charging device is on, the battery has been discharged too much. In this case the MotorAnalyzer must be switched off and you need to wait until the 12V LED at the charging
device is on again. If the 24V LED at the charging device is on, the charging device is not connected to the MotorAnalyzer correctly and the MotorAnalyzer is not being charged.
3 Front view, operating elements and connections

The MotorAnalyzer is switched on at the back panel. After switching on, the MotorAnalyzers shows the following display:

Start button Display Function buttons Selection button for test methods Connection sockets / High voltage setting / High voltage connection sockets

The start button also has the function of a Start and Stop button. After a test has been started in continuous operation, it is also stopped via this button.

The selection button for test methods serves to select the desired test method.

Via the high voltage setting, the desired voltage level is adjusted manually.

Attention!!

Only use measure leads with safety plugs at the connection sockets. They serve as touch-guard and have a much longer sparking distance!
3.1 Function buttons S1...S4

The manual often refers to the buttons S1 ... S4 they can be found below the display. Depending on the test method, they have different functions, which are found above
the buttons on the display.

Here, the button S2 meaning okay is to be activated.

Within the operating manual, the buttons are often displayed as follows.

Example: display and explanation of the buttons
SetUp
The SetUp for this test method can be opened by activating the button S1.
Help
If you activate the button S3, the help text will be indicated.

3.2 Graphic symbols on the display
The coils that are being tested are indicated via symbols. The coil between U and V has this symbol: The 3 dots stand for the 3 measure connections at the tester. The symbol below stands for
the coil.

Coil at UV in comparison to coil at VW. The symbols stand for the 3 connection sockets of the tester and for the coil that is measured.

Coil at UV in comparison to the reference with result indication. The symbols stand for the 3 connection sockets of the tester and for the coil that is measured.


4.1 Auto. Test: automatic analysis at a 3-phase stator (without reference)

Test method for fast motor testing are the resistances and inductivities in the stator/motor equal?

With the Auto. Test, the resistance and the surge test is executed automatically after starting the tester. The resistances and the surge curves are compared. The deviation of the
tests in percent is calculated. Depending on the maximum allowed tolerance, the deviations are evaluated as go / no go. If the MotorAnalyzer can identify certain clear faults,
they will be indicated on the display.

Connection method SetUp Display
U V W Frame
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^Surge.Tol= 10% : Maximum allowed deviation of the surge curves in percent
The result is indicated via a symbol
symbol for go results
symbol for no go results
^Resis.Tol= 10% : Maximum allowed deviation of the resistances in percent
Connection= star/delta : This input is necessary for the MotorAnalyzer for being able
to make clear fault statements.
with Refer= no |no : the 3 coils are compared
|yes : the 3 coils are compared to reference oscillations (of a
reference stator) stored before
Resis.Tol.= 10% : Maximum allowed deviation of the resistances from the set
value (to be found in the SetUp of the resistance test)
For the comparison between the phases, this input is
irrelevant!

Surge = deviation of surge voltage
open = disconnection
Short = short circuit
Resis. = resistance deviation
result = evaluation
iO = go = OK
niO = no go = not OK

Activate the SetUp button S1 at the front panel of the tester in order to open the SetUp. For starting and stopping the test, please use the Start/ Stop button on the front panel.

SetUp
Activating the button S1 opens the SetUp for this test method.
Help

The dotted connection leads indicate measure leads for the 4-wire resistance measurement. For more detailed information, please refer to the resistance test.

For further explanations and tips on the 4-wire resistance measurement, please also refer to the glossary.

After an Auto. Test, in order to see the oscillation or the resistance values, you can turn the selection button for test methods to Surgetest or Resistance.

In order to get a tip on how to measure twisted wires, please refer to the glossary.

4.2 Auto. Test: automatic analysis at a stator (with reference)

Test method for small-sized production are the resistances and inductivities equal compared to a reference stator?

With the Auto. Test, the resistance and the surge test is executed automatically after starting the tester. The resistances and the surge curves are compared to a reference. The
deviation of the tests to the reference in percent is calculated. Depending on the maximum allowed tolerance, the deviations are evaluated as go / no go.
Since it is compared to the reference and no longer between the phases, automatic testing is possible at both 3-phase and 2-phase stators.

U V W Frame
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^Surge.Tol= 10% : Maximum allowed deviation in percent between the surge curves
^Resis.Tol= 10% : Maximum allowed deviation in percent between the resistances
Connection= star/delta : This input is necessary for the MotorAnalyzer for being able
to make clear fault statements.
With Refer= no |no : the 3 coils are compared
|yes : the 3 coils are compared to reference oscillations (of a
reference stator) stored before
Resis.Tol.= 10% : Maximum allowed deviation of the resistances from the set
value (to be found in the SetUp of the resistance test)

Surge = deviation of surge voltage
open = disconnection
Short = short circuit
Resis. = resistance deviation
result = evaluation
iO = go = OK
niO = no go = not OK


SetUp
Refer
Use currently measured stator as reference stator. Both, the surge curves and the measured resistance become reference. After this, the test is always done by comparing the reference
curves.
NoRef
Cancel the current reference. After this, you will have the standard comparison of the phases.
Help

The dotted connection leads indicate measure leads for the 4-wire resistance measurement. For more detailed information, please refer to the resistance test.

For further explanations and tips on the 4-wire resistance measurement, please also refer to the glossary.

The principle of comparing to a reference is explained in chapter 5.3 Surge test with reference.

After an Auto. Test, in order to see the oscillation or the resistance values, you can turn the selection button for test methods to Surgetest or Resistance.


5.1 Surge test: Stator or coil test with comparison between the individual phases

The individual coils of a stator are compared automatically. At the end of the test, the deviation of the surge curves is indicated in percent. In relation to the maximum allowed
tolerance, the deviations are evaluated as go / no go.

U V W Frame
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Phases....= 3-phase |3-phase: Compares between the 3 phases (3-phase stator)
Meas. type= Single |Single : Single test with indication of deviation in percent
|Continu: Continuous test
Type......= Stator |Stator : Test at a stator (motor without armature)
|Motor : Test at a completely assembled motor
with.Refer = no |no : The 3 coils are compared to each other
|yes : The 3 coils are compared to reference oscillations
(of a reference stator) stored before.
Surge.Tol.= 10% |xx% : max. allowed deviation between the phases
The test result go / no go is
indicated in front of the deviations.
Symbol for a go result
Symbol for a no go result

U V W Frame
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Phases....= 2-phase |2-phase: Compares between the 2 phases (main / auxiliary winding)
with.Refer= no |no : The 2 coils are compared to each other
|yes : The 2 coils are compared to reference oscillations

U V W Frame
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Phases....= 1-phase |1-phase: no phase comparison only simple surge test
Meas. type= Single |Single : One single test without evaluation
|Continu: Continuous test without evaluation
with.Refer= no |no : No automatic comparison possible, because only one coil
is measured.
|yes : The coil is compared to a reference oscillation

For activating the SetUp input, please select button S1 SetUp at the front panel of the tester. For starting and stopping the test, please select button Start/Stop at the front panel.

For testing, the stack of the motor can also be connected. A short circuit to the frame can be measured, too. However, the connection of the frame is no precondition for the test.

Please also refer to the glossary for further explanations and tips on the surge test.

The phases are compared with each other and the deviation is calculated.
When testing with 3 phases, there will be 3 deviation values.
When testing with 2 phases, there will be 1 deviation value.
The deviation values are indicated in percent.

This example shows a stator without deviation between the phases.

This example shows a stator with deviations between the phases.

U V W Frame
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U V W Frame
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5.2 Surge test: Armature test, field test or testing of individual coils

The best way of comparing armatures, fields and individual coils automatically is to use one coil as a reference and use this reference for comparing.
At the end of the test, the deviation of the latest measured oscillation to the reference oscillation is indicated in percent. In relation to the maximum allowed tolerance, the
deviation is evaluated as go / no go.


U V W Frame
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Phases....= 1-phase |1-phase: no phase comparison only simple surge test
Meas. type= Continu |Continu: Continuous test with indication of the deviation in percent
(if with.Refer=yes)
with.Refer= yes |no : No automatic comparison possible, because only one coil
is measured.
|yes : The coil is compared to a reference oscillation
stored before


Teaching-in reference oscillation
A. Proceedings for teaching-in the oscillation:
Execute test at the sample coil and end the test.
Select button S2 Store -> the oscillation of the latest test will be copied into the internal reference storage of the tester. Instead of being compared to each other, now all tests are compared
to the oscillation in the reference storage.
Continue with further tests.

B. Proceedings for teaching-in a new oscillation:
Select button S2 Clear -> it will no longer be compared to the stored reference oscillation. Now, please continue with teaching-in the new reference as described under A.

Example: execute armature test
Execute test between 2 lamellas via test probes. The best oscillation can be found in the lamella distance that corresponds to the brush distance. It would be best to mark the lamellas between which
you have tested.
Select button S2 Store. -> the oscillation of the latest test will be copied into the internal reference storage of the tester (please see Teaching-in reference oscillation).
Start test
Now, move the test probe by one lamella each. There will be an automatic comparison to the reference oscillation taught-in before. As soon as the test probes lose contact to the test object, the
display will indicate the following text: offen: U-V. The tested lamellas could be marked.

Attention! Armatures can have uneven winding numbers or compensating windings! In this case, always deviations can be detected they
continuously repeat, however. The comparison would be based on the fact that the deviations need to repeat themselves continuously e.g. all 3 lamellas.

5.3 Surge test: Stator or coil test with phase comparison to a reference stator

The individual coils of a stator are automatically compared to a sample stator (go reference) that has been taught in before. At the end of the test, the deviation of the surge
curves compared to the reference is indicated in percent. In relation to the maximum allowed tolerance, the deviations are evaluated as go / no go.
The comparison to a reference is small-sized batch testing. The tester automatically compares the stators to a taught-in go sample.

U V W Frame
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Phases....= 3-phase |3-phase: Compares 3 coils to the reference
with.Refer= yes |yes : The 3 coils are compared to reference stator
stored before
The test result go / no go is indicated
in front of the deviations.

U V W Frame
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Phases....= 2-phase |2-phase: Compares 2 coils with the reference
with.Refer= yes |yes : The 2 coils are compared to reference stator
stored before
incicated in front of the deviations.

U V W Frame
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Phases....= 1-phase |1-phase: Compares a coil to the reference
Type......= Stator |Stator : Single test with indication of deviation in percent)
with.Refer= yes |yes : The coil is compared to a reference stator
stored before


For testing, the stack of the motor can also be connected. A short circuit to the frame can be measured, too. However, the connection of the frame is no precondition for the test.

Principle of comparing to a reference

When comparing a stator to a reference, first the oscillations of a go stator are measured and then stored in
the tester as reference. At the next test, the oscillations are not compared to each other but to the stored
reference.

The oscillations at the individual coils can be very different. Since the individual oscillations are no longer
compared to each other but with the stored reference, this is not important, though.
U V W Frame
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Teach-in reference oscillations

A. Proceedings for teaching-in the oscillation:
Execute test at the sample coil and end the test.
Select button S2
Refer
-> the oscillation of the latest test will be copied into the internal reference storage of the tester. Instead of being compared to each other, now all tests are
compared to the oscillation in the reference storage.
Continue with further tests.

B. Proceedings for teaching-in a new oscillation:
Select button S2
NoRef
-> it will no longer be compared to the stored reference oscillation. Now, please continue with teaching-in the new reference as described under A.

Examples of displays

The displays below give one example of go and and one example of a no go result:

go with 0% deviation no go with 37% deviation

If possible, the MotorAnalyzer indicates the fault in words, also. The picture below shows a test with open connection:

5.4 Surge test: 3-phase motor test with phase comparison between the 3 phases

This motor test is to be applied, if the surge test at the motor with the standard stator test (chapter 5.1) shows too large deviations between the 3 phases.
Explanation: At surge tests at motors it can, owing to the armature, come to apparent differences in the 3 phases. Depending on the angular position of the armature, the 3 phases are influenced by
the armature differently. At one position of the armature, for example, phase one shows a deviation at another position, e.g. phases 2 and 3 show a deviation. If the motor to be tested shows this
physical effect, the test method described below needs to be applied.
In this case, the individual coils of a motor are automatically compared with each other, also. However, no oscillations (which are different, anyway), but the deviation in percent between the phases is
displayed in the form of a bar graph. From measurement to measurement, now the armature needs to be turned for one complete revolution by hand. Doing this, the three bars (the 3 deviations in
percent) are indicated from measurement to measurement with different lengths. The maximum deflection that ever occurred during the measurement, is indicated by a vertical line (maximum value
storage). At the end of the complete revolution, 3 vertical lines for maximum value should be lying upon each other at the same position. Otherwise, there is probably a fault.

U V W Frame
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Phases....= 3-phase |3-phase: Compares between the 3 phases (3-phase stator)
Meas. type= Single | : For the motor test, this setting is irrelevant
Continu
Type......= Motor |Motor : Test at a completely assembled motor
with.Refer= no/yes | : For the motor test, this setting is irrelevant
Surge.Tol.= 10% | : For the motor test, this setting is irrelevant

The 3 bars show the deviations of the
individual phases in comparison with
each other

ATTENTION: Do no switch on the motor during the test. This would destroy the MotorAnalyzers. For safety reasons, we recommend to
disconnect motors before!

SetUp
Help


6.1 Resistance test: Stator or coil test with or without set values

The individual coil resistances of a stator are automatically measured and compared to a nominal resistance. At the end of the test, the deviation between the resistances is also
indicated in percent. Depending on the maximum allowed tolerance, the deviations are evaluated as go / no go.

U V W Frame
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Phases....= 3-phase |3-phase: Automatic test of all 3 phases (3-phase stator)
|Continu: Continuous test with indication of deviation in percent
after the test
test PTC = no |no : normal coil test without current limitation up to max. 1.5A
test current
Ru-Rv.....= 1.00 Ohm| : Nominal resistance between U and V
Rv-Rw.....= 1.00 Ohm| : Nominal resistance between V and W
Ru-Rw.....= 1.00 Ohm| : Nominal resistance between U and W
Tolerance.= 10% |xx% : Maximum allowed deviation from the nominal resistance
in percent
The result is indicated by the following symbols:
symbol for a go result
symbol for a no go result
Test time.= 1.0 s | : Test time in seconds. Small stators should be tested with
a short test time and large stators with a long test time.
This test time is only relevant for the single test. If the
test is too short, measure errors will occur.
(Please also refer to the glossary.)
Temperatur= 22.0 Ce | : Since the copper resistance strongly depends on the
temperature, the test result can be compensated to 20 degrees
Celsius.
If the tester has no ambient temperature sensor, the actual
ambient temperature can be entered manually, here.

U V W Frame
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Phases....= 2-phase |2-phase: Compares between the 2 phases (main / auxiliary winding)
Meas. type= Single |Single : Single test with indication of the deviation in percent
|Continu: Continuous test with indication of the deviation in percent
after the test
test PTC ?= no |no : normal coil test without current limitation up to max. 1.5A
test current
Rv-Rw.....= 1.00 Ohm| : Nominal resistance between V and W
Ru-Rw.....= irrelev.| : has no meaning
in percent
Test time.= 1.0 s |yy s : Test time in seconds. Small stators should be tested with
Celsius. If the tester has no ambient temperature sensor, the
actual ambient temperature can be entered manually, here.


U V W Frame
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Phases....= 1-phase |1-phase: no phase comparison only simple resistance test
Meas. type= Single |Single : One single test
test PTC ?= no |no : normal coil test without current limitation up to max. 1.5A
test current
Rv-Rw.....= irrelev.| : has no meaning
in percent


Depending on the resistance value, a high test current of max. 1.5A is flowing at the resistance test. This must be considered for testing low-ohmic resistances. Resistances
with low power can be damaged during the test. However, this doesnt refer to windings. (see test current table in the glossary)

In case of resistances below approx. 1 Ohm, good measure results can only be obtained with the 4-wire resistance measurement. For supplying the test current, 2 measure
leads are connected to the test object, and 2 further measure leads are connected for measuring the voltage drop at the test object. With the voltage and the current, the
resistance is calculated. (see glossary)

The pictures show the 4-wire resistance measurements with dotted lines. These leads must not be used however, the measure error at small resistances becomes continuously larger.

SetUp
Remem
If you activate the button S2, the latest measured values will be stored after the test. In the SetUp, the nominal resistance values are replaced by the measured actual values. At a
1-phase test, after re-starting the test, the deviation to the stored measure value is displayed graphically.
Help

For further explanations and tips, please also refer to the glossary.

When testing, the battery symbol is indicated. If the voltage is below 11V, the accumulator is damaged and the test results could become
faulty. This applies to all tests.

The resistance test at small resistances strains the accumulator considerably, because a high test current is flowing. The lower the charge of the accumulator, the lower the test current becomes. This
can lead to measure errors. For the resistance test, it would therefore make sense to operate the MotorAnalyzer at the charging device.

Schleich GmbH will assume no liability or claim for damages, if the MotorAnalyzer damages a motor.
Below please find the explanation of the characters on the screen:

Measure value related to 20 Celsius.

Measure value between U and V Result OK compared to set value

Measure value between V and W

Measure value between U and W

Deviation (Delta) compared to average

At a 3-phase or 2-phase resistance test, the MotorAnalyzer calculates the average with the 3 or 2 test results. In relation to the average, the MotorAnalyzer calculates the deviations of the individual
phases. The result of the deviation is indicated in percent.

During the test, a symbol marks the phase that is being tested.

If you use the 4-wire test probes, the attacable start switch can be very practical. Although having a test probe in every hand, you can still switch the tester on and off easily.

6.2 Resistance test: PTC thermistor detector test

PTC thermistors must only be tested with a reduced test current. Therefore, the normal resistance test must not be used, because the test current can become much too high.
The result could be the destruction of a temperature probe.

For reducing the test current, you have to go to the SetUp of the resistance test.

When selecting the resistance test via selection button for test methods, you will automatically be asked, whether you want to
execute a PTC thermistor test or not. The pre-condition for this question is that in general SetUp of the tester the PTC-inquiry
has been set to yes. Please also refer to the chpter SetUp later in this manual.

ATTENTION! It is not advisable to activate the PTC thermistor test repeatedly. When measuring
resistances below 10Ohm, this would lead to considerable measuring errors.
If, by accident, small resistances are measured with the PTC thermistor test, a warning message will appear on the display: Attention:
faulty measurement!. At this point, at the latest, the PTC thermistor test should be switched off.

U V W Frame
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Phases....= 1-phase |1-phase: no phase comparison only simple resistance test
Meas. type= Single |Single : One single test
test PTC ? = yes |yes : Resistance test with current limitation to max. 2.6mA
Ru-Rv.....= 800.00 | : Nominal resistance of the PTC
in percent
Test time.= 0.0 s | : Test time in seconds
Temperatur= 22.0 Ce | : has no meaning / for the PTC test, it is automatically
deactivated

SetUp
Remem
If you activate the button S2, the latest measured value will be stored after the test.
Help

For further explanations and tips, please also refer to the glossary.


Schleich GmbH will assume no liability or claim for damages, if the MotorAnalyzer damages a motor.

6.3 Resistance test: Armature, field or single coil test

The best way to compare armatures, fields and single coils is to memorize the resistance value of a coil and then compare against this value.
If the Remem button S2 is activated after a test, the MotorAnalyzer can memorize the value for the operator. Now, the test is restarted and, in addition to the measure value,
the display shows a bar, which indicates the deviation of the measure value to the memorized value.

U V W Frame
+HV
High Voltage
Krper
R
PE

Phases....= 1-phase |1-phase: Test only between U and V
Meas. type= Continu |Continu: Continuous test with indication of the deviation in percent
if the measure value has been remembered.
in percent

For testing, we recommend our 4-wire test probe, article number
4000395. With this test probe, the lamellas of stators can be
contacted ideally.

The test probes are well-suited for the application in workshops.
A protecting cap protects the test probe tips when they are not
being used!

For the test probes, an attachable start / stop switch is also
available. It enables comfortable working.

For remembering the value,
please activate this button.
After this, the deviation to the
remembered value will be
indicated.

SetUp
Remem
If you activate the button S2, the latest measured value will be stored after the test. Now restart and measure from lamella to lamella.
Help
In case of DC armatures it must be taken into consideration that equalizers influence the result. Equalizers can cause continuously repeating deviations.

For further explanations and tips, please refer to the glossary.
7 High voltage test

The MotorAnalyzer executes the high voltage test with a direct voltage.

The final high voltage test in compliance with VDE at motors is always executed with alternating voltage. Therefore, this direct voltatge test can not
replace the VDE test with alternating voltage.

see also chapter high voltage tester GLP11eHV

However, this test can be used for trouble shooting.

The test current is limited to a current specified by the VDE in VDE0104. It is, therefore, possible to perform the high voltage test without the touch
guard that would normally be necessary. However, the standards also require that the load stays below 350mJ. When testing larger motors, however, the load
is often much higher, which requires the respective protective measures. I.e. touching the high voltage should be avoided, because you could suffer a
dangerous electric shock. The enclosure of the MotorAnalyzer is connected to the minus pole of the high voltage. I.e. touching the enclosure and touching the
plus pole leads to an electric shock.

Please also refer to the glossary for further explanations and tips on the high voltage test.

U V W Frame
+HV
High Voltage
Krper
R
PE

U V W Frame
+HV
High Voltage
Krper
R
PE

Mode......= manual.| manual.: Via the adjusting potentiometer, the high voltage is adjusted
manually to the desired level.
The test continues until it is stopped via the Start/Stop
button.
|automat : The high voltage is automatically adjusted to the value
entered at Unominal. After this, the test time elapses
automatically. When the time is over, the test ends
automatically.
If the limit current Imax is exceeded during the test, the
result will be no go: This will also be indicated via an
acoustical signal.
Unominal..= 1000 V | : Test voltage that is set in the automatic mode.
Imax......= 0.5 mA | : Maximum allowed test current. If exceeded the test is no go.
Only applies to automatic mode!
Test time.= 1.0 s | : Test time in seconds for the automatic mode.
Steps.....= 1 : In the automatic mode, the voltage can automatically be
increased in up to 10 voltage steps from 0Volt to Unominal.


ATTENTION! Please remove the surge or resistance test leads from the motor/stator for the test.
The adjustment of the voltage level is determined by the respective standards.

The most simple rule is: Utest = Unom * 2 + 1000. Here, twice the nominal voltage of the motor + 1000V is connected to the test object. Depending on the age of the motor, an increase or decrease
of the test voltage is possible.
The indicated voltage refers to a test with alternating voltage. Since the MotorAnalyzer executes the tests with direct voltage, the direct voltage can usually adjusted to the peak value of the
alternating voltage. This results in a test voltage that is higher than the effective value of the alternating voltage by 2 (= 1,414).

ATTENTION! During the test, the test object will be loaded. At the end of the test, the test object therefore must always be discharged. Otherwise, the
operator could suffer an electric shock when touching the test object.

Indication of residual voltage after switching off

After switching off the high voltage, the tester indicates the residual voltage of the test object. The residual voltage is reduced by internal resistances inside the tester and in
the test object or via an external discharge. As soon as the residual voltage has fallen below 60V, the tester gives an acoustic signal and the residual voltage will no longer be
indicated.

SetUp
Help

The battery symbol is also indicated during the test. If the voltage is below 11V, the accumulator is damaged and the test results could
become faulty.


8 PI/DAR test : (PI) Polarization index / (DAR) dielectric absorption relation

The PI or DAR is tested fully automatically. On the basis of the time/resistance ratio, the PI supplies information about the insulation. For the PI, the test voltage is connected to
the test object for more than 10 minutes. This causes a polarization of the charge carriers in the insulation i.e. an orientation of the charge carriers towards the field lines. If
the charge carriers are still mobile, this can be measured at the beginning of the test via an additional polarization current. The higher current with constant test voltage results
in a lower resistance. At the end of the test (after 10 minutes) all charge carriers should be polarized, so that the resistance increases again. The better the mobility of the charge
carriers in the insulation, the better is the insulation of the test object. This is indicated by a high PI. The PI is therefore an indicator for the age of an electric machine. Storing
the insulation resistance and the PI of a motor in regular intervals and comparing the measure values for months or years supplies the information, whether a machine needs
maintenance.

At this automatically executed test, the insulation resistance at the end of the test is compared to the insulation resistance at the beginning of the test.
The difference between the PI and the DAR is the varying test time.
PI = R10min / R1min (or I1min / I10min) test time = 10 minutes (The PI is used for electric motors and other products.)
DAR = R60sec / R30sec (or I30sec / I60sec) test time = 1 minute (The DAR is normally only used for cables.)
The complete test is executed fully automatically. An acoustical signal indicates, when the first and when the last measure value is read in. Now the test is ended and the high
voltage is switched off automatically. After this, the respective index is indicated.
In case the test is ended by activating the Start/Stop button, no index will be indicated.
The insulation resistance is measured with high voltage via the connection sockets of the high voltage test.


Please also refer to the glossary for further explanations and tips on the high voltage test and explanations concerning the PI.

U V W Frame
+HV
High Voltage
Krper
R
PE

Mode:.....= manual.
manual. : Via the adjusting potentiometer, the high voltage is adjusted
The test is performed automatically, or it is stopped via the
Start/Stop button.
automat : The high voltage is automatically adjusted to the value
automatically or it is stopped via the Start/Stop button.
PI/DAR....= PI : Selection of PI or DAR test
Unominal..= 1000 V : Test voltage that is adjusted in the automatic mode.



The adjustment of the voltage level is determined by the respective standards.

The most simple rule is: Utest = Unom * 2 + 1000. Here, twice the nominal voltage of the motor + 1000V is connected to the test object. Depending on the age of the motor, an increase or decrease
of the test voltage is possible.
The indicated voltage refers to a test with alternating voltage. Since the MotorAnalyzer executes the tests with direct voltage, the direct voltage can usually adjusted to the peak value of the
alternating voltage. This results in a test voltage that is higher than the effective value of the alternating voltage by 2 (= 1,414).


Nach dem Abschalten der Hochspannung, zeigt der Tester die noch am Prfling anliegende Restspannung an. Diese wird durch interne Widerstnde im Tester sowie im
Prfobjekt oder durch eine externe Entladung abgebaut. Sobald die Restspannung unter 60V abgefallen ist, gibt der Tester einen akustischen Signalton ab und die Anzeige der
Restspannung erlischt.

SetUp
Help

The battery symbol is also indicated during the test. If the voltage is below 11V, the accumulator is damaged and the test results could
become faulty.


If you want to repeat the PI test, you should wait approx. 1 hour after the last PI test. The motor needs this time to depolarize. Otherwise, you will have bad measuring results. For the 1-hour
waiting time, it is essential that the motor is discharged between the test connections. We recommend to connect them for this purpose.

9 Insulation resistance test

The insulation resistance is measured with high voltage via the connection sockets of the high voltage test.


Please also refer to the glossary for further explanations and tips on the high voltage test

U V W Frame
+HV
High Voltage
Krper
R
PE

Mode......= manual.
manual. : Via the adjusting potentiometer, the high voltage is adjusted
The test continues until it is stopped via the Start/Stop
button.
automat : The high voltage is automatically adjusted to the value
automatically. When the time is over, the test ends
automatically.
Rmin......= 2.00 : In the automatic mode, the test also has an automatic
evaluation. Here, this minimum resistance value must not be
fallen below.
Test time.= 1,0 s : Test time in seconds for the automatic mode.
Unominal..= 1000 V : Test voltage that is set in the automatic mode.
Steps:....= 1 : In the automatic mode, the test voltage can automatically
be increased in up to 10 voltage steps to Unominal.
Graphics..= no no : The measure values are indicated graphically.
yes : The measure values are indicated in a graphical diagram.
Only available in mode Automatic.
ISO-Scale.= 10 GOhm : Maximum value of vertical axis in graphics mode.
Smoothing.= medium none : No averaging. The test is fast, but the measure values are
unsteady.
medium : Weak averaging. The test is somewhat slower.
high : Strong averaging. The test is slow, but the display is steady.

no graphics

graphics display


The insulation resistance value partly depends on the level of the test voltage. Especially very high resistances can only be measured with increased test voltage. Otherwise, measuring errors
occur. We recommend, if the test object allows this, a test voltage of at least 1000V.
In case of extremely high resistance values, even touching the measuring leads has a negative effect. For the evaluation of the measuring value, this must be taken into consideration. If high
insulation resistances (in the G range) are to be measured reliably and stable, our special test lead needs to be used.


After switching off the high voltage, the tester indicates the residual voltage of the test object. The residual voltage is reduced by internal resistances inside the tester and in
the test object or via an external discharge. As soon as the residual voltage has fallen below 60V, the tester gives an acoustic signal and the residual voltage will no longer be
indicated.

SetUp
VDE
Activating the button S2 will activate the VDE standard values for testing repaired machines.
Help

The battery symbol is also indicated during the test. If the voltage falls below 11V, the battery is damaged and the test results can become
faulty.


If the insulation resistance is measured at devices of class II (devices without PE because case insulated), the test will be done between the current-carrying leads to the metal parts of the case (e.g.
screws, etc.).

The current-carrying leads (L+N) must be connected with each other and the mains switch at the test object needs to be switched on, so
that all leads are included in the test.

If L+N are not bridged, the test is first to be executed at one pole (e.g. at L) against the metal parts and then a second time from the other
pole against the metal parts.

Please also refer to the glossary for further explanations and tips on the insulation resistance test after the step voltage method.

U V W Frame
+HV
High Voltage
Krper
R
PE

10 PE test

The PE test is performed at repaired devices according to standards. A test current of at least 200 mA DC must be flowing through the PE that is to be tested once in positive
and once in negative direction. The higher of the two values is the PE resistance. For the PE test, the resistance test of the MotorAnalyzer is used. Therefore, the polarity of the
test current must be done via manually exchanging the test probe tips.

U V W Frame
+HV
High Voltage
Krper
RPE

Normal test (R+ test)

U V W Frame
+HV
High Voltage
Krper
RPE

Test with changed poles (R- test)

Rmax......= 0.20 : Maximum allowed resistance at PE test
Test time.= 1.0 s : Test time in seconds for the automatic mode.

The test is performed with an automatic evaluation.

For this test, it can be helpful to use the release switch at the test probe.
Article number: 403111

U-Sense
Strom

Please use the 4-wire configuration for the PE test.

R+ test result

R- test result


The test is executed in two steps:
After starting the test, a test probe behind the R+ test indicates the test of the resistance at normal polarity. Now, the resistance needs to be measured and the test is to be confirmed via the start
button.
Now, the measure leads must be twisted. The test probe behind the R- test now indicates that the resistance is to be measured with reversed polarity.
The larger of the two resistance values is the measured PE resistance. None of the two resistance values must be above the limit value Rmax.

Like at the PE resistance test, the resistances in the measure leads are measured, also. In order to avoid this, it is possible to apply the 4-wire resistance measurement.

SetUp
VDE
Activating the button S2 will set the VDE standard values for testing repaired machines.
Help

Please also refer to the glossary for further explanations and tips.
11 Neutral zone adjustment

The neutral zone adjustment serves for adjusting the angular position of the brush rocker at a DC motor. The adjustment might already be necessary after exchanging the
brushes, at the latest after repairing the motor.

A special set of cables, which needs to be ordered separately, is necessary for the neutral zone adjustment.
Two leads serve for connecting the armature and two leads serve for connecting the field.

When testing, the deviation from the neutral zone point is indicated digitally and via a bar graph.
It is best to start the adjustment with a sensitivity of the display that is not too large. First, you try to find the neutral point roughly by twisting the brush rocker that is still loose.
Now, the sensitivity of the tester is increased in order to be able to adjust the point more accurately.

Connection method Measure leads Display

RS232 Sonden
MotorAnalyzer

A special set of cables is necessary for the test.

red = field
black = armature (brushes)

aricle number: 403102

For starting and stopping the test, please select button Start/Stop at the front panel.

The armature connections must always be connected directly at the brush. If the motor had additional poles (e.g. commutating poles), this would
otherwise result in a faulty adjustment. Auch bei Reihen- bzw. Nebenschlussfeldern ist auf die Trennung der Leitungen zwischen Feld an Anker zu
achten!

-
Activating the button S1 decreases the sensitivity.
+
Activating the button S2 increases the sensitivity.
Help

Clamp definitions: - armature A1 and A2 (or A, B) field separately excited F1 and F2 field self-excited E1 and E2

12.1 Sense of rotation test at stators

For the sense of rotation test, the stator must be connected to 3-phase current. For this purpose, it is usually connected to the test field. For testing, already a small test voltage
of approx 30V is sufficient for activating the sensor.
It is best, first to set 0Volts at the test field. Now you put the rotary field sensor into the stator (see picture) and starts the test. Now you increase the test voltage until the
MotorAnalyzer indicates a rotary field.

ATTENTION! When adjusting the test voltage, the current consumption of the stator must, of course, be taken into consideration. Under no circumstances,
it should exceed the nominal current of the motor.

Connection method SetUp and measure leads Display

RS232 Sonden
MotorAnalyzer

3-phase motor 1-phase motor

Rotat.Dir.= Stator : Select rotation test at the stator with hall probe.

A special rotary field probe with integrated Hall elements is necessary for the test.

Article number: 403103

In case of motors with higher pole numbers, it could be possible that the rotary field cannot be measured at an optimum. In this case, it could help to move the probe in the stator or to turn the
stator slightly. At stators with extremely high pole numbers, it might be necessary to move the probe through the stator completely once and to monitor the course of the signal. The rotary field,
which is indicated by the tester most is to be used. For special cases, we can deliver further rotary field probes with different designs.

Help

PLEASE NOTE The rotary field can also be measured at 1-phase motors. Please refer to the respective connection diagram.
12.2 Sense of rotation test at motors

For the sense of rotation test, the motor connected in star or delta is connected to the MotorAnalyzer via 3 test leads. It must be made sure that the test leads U, V and W
(colored like the sockets at the front panel) are connected to the terminal board accordingly. Otherwise, the indicated sense of rotation is wrong.
For performing the test, the correct input must be effected in the SetUp of the tester. The sense of rotation must be set to motor. Now the tester is started and the motor shaft
is turned in one direction. The MotorAnalyzer will then indicate the sense of rotation, which should, normally, viewed from the A-side of the motor (shaft side) be turning right
(clockwise).

Sense of rotation OK, if:
You are turning clockwise and the MotorAnalyzer indicates clockwise or you are turning counter-clockwise and the MotorAnalyzer indicates counter-clockwise.
Sense of rotation not OK, if:
You are turning clockwise and the MotorAnalyzer indicates counter-clockwise or you are turning counter-clockwise and the MotorAnalyzer indicates clockwise.

Connection method SetUp and measure leads Display

RS232 Sonden
MotorAnalyzer

Rotat.Dir.= Motor : Select the manual rotation of the motor shaft.

In addition, measure lead 403112 is necessary for this test method.

Testing at 3-phase motors Testing at single-phase motors

In case of message:
? / Rotate faster ?
the MotorAnalyzer cannot perform
the test. In this case, the shaft
must be rotated faster.


SetUp
Help

PLEASE NOTE This test is only suitable for 3-phase short-circuit motors.
U V W
U V W

13 Field strength test

Via a field probe, the field strength and ist polarity is detected. It is indicated graphically on the screen.

RS232 Sonden
MotorAnalyzer

A special rotary field probe with integrated Hall elements is necessary for the test.

Article number: 403108 or 403105


Help
14.1 Inductivity test - turn-to-turn test: at stators

Turn-to-turn tests are usually executed via the surge test.

Alternatively, the turn-to-turn test can be executed with a special test probe. Via a transmitting coil, this test probe launches a magnetic alternating field into the stator. Via a
receiving coil, also integrated into the test probe, the reaction of the stator is measured. If the stator has a short circuit in the winding, the reaction (the deflection of the
MotorAnalyzers) is stronger at the point of fault than at the coils without faults.

For testing, the test probe for turn-to-turn faults is brought down exactly over one slot of the stator. With the test probe you now go once through the complete stator testing all
slots. The individual measure values are compared to each other. In case of a fault-free test object, you should find no or only small deviations between the individual measure
values.

RS232 Sonden
MotorAnalyzer

For the test, a special test probe for turn-to-turn faults is necessary.

Article number for 9mm slot distance: 403106


At the beginning of the test, the
amplifier is always 10. As soon as
the measured voltage exceeds
0.5V, the amplifier automatically
goes back to 1 and remains at this
value until the test is over.


When testing, the MotorAnalyzer always balances to an optimum test result. The precondition is to first bring the probe down on a slot inside the stator and only after this start the test.

Help
-
If you activate the button S1, the sensitivity will be decreased.
+
If you activate the button S2, the sensitivity will be increased.
Remem
If you activate the button S3, the latest measured value will be stored. The stored bar length is indicated on the display via a vertical arrow. This makes it much easier to compare the
other measure values to this reference point.
-.
14.2 Inductivity test - turn-to-turn test: at armatures

Turn-to-turn tests are usually executed via the surge test.
Alternatively, the turn-to-turn test can be executed with a special test probe. Via a transmitting coil, this test probe launches a magnetic alternating field into the armature. Via a
receiving coil, also integrated into the test probe, the reaction of the armature is measured. If the armature has a short circuit in the winding, the reaction (the deflection of the
MotorAnalyzers) is stronger at the point of fault than at the coils without faults.

For testing, the test probe for turn-to-turn faults is brought down exactly over one slot of the armature. With the test probe you now go once through the complete stator testing
all slots. The individual measure values are compared to each other. In case of a fault-free test object, you should find no or only small deviations between the individual
measure values.

RS232 Sonden
MotorAnalyzer

For the test, a special test probe for turn-to-turn faults is necessary.



At the beginning of the test, the
amplifier is always 10. As soon as
the measured voltage exceeds
0.5V, the amplifier automatically
goes back to 1 and remains at this
value until the test is over.


When testing, the MotorAnalyzer always balances to an optimum test result. The precondition is to first bring the probe down on a slot inside the stator and only after this start the test.

Help

-
If you activate the button S1, the sensitivity will be decreased.
+
If you activate the button S2, the sensitivity will be increased.
Remem
If you activate the button S3, the latest measured value will be stored. The stored bar length is indicated on the display via a vertical arrow. This makes it much easier to compare the
other measure values to this reference point.
Via the button S4 you can activate or deactivate an acoustical signal. It will indicate via a beep that a test result is roughly the same as a stored test.

In case of DC armatures it must be taken into consideration that equalizers influence the result. Equalizers can cause continuously repeating deviations.

15 SetUp

In the SetUp, the general settings of the tester can be adjusted.

SetUp Darstellung
Language..= Germany : Language of the display of the MotorAnalyzer (German, English, Italian)
Clear Memo= no : The MotorAnalyzer has an integrated result storage. By activating the button S4, the test
Results are temporarily stored in this storage. With the software PrintCom, the test results
can be read out of this storage and transmitted to PrintCom.
In case the storage is full, and no PrintCom can be connected at the moment, this function can
be used to delete the complete temporary storage.
PrintCom..= yes/no yes : The internal result storage for temporary storage for PrintCom can be switched on or off. For
using the PC software PrintCom, a yes must be entered, here.
no : PrintCom is not being used the internal result storage is off.
WithPassw.= no : For this software version, this setting is irrelevant.
Password..= 123 : For this software version, this setting is irrelevant.
Contrast..= 128 : Contrast of the display
BasicTemp.= 20 : Basic temperature, to which, at the resistance test, the measured resistance value is related to
in dependence on the temperature (please also refer to the Glossary - Ambient temperature)
PTC-quest.= yes : When selecting the resistance test via the Selection button for test methods, you will see
the message that the PTC test with high current can destroy the PTC. Here you can
enter whether you want the PTC test to be executed or not.

Activate the SetUp button S1 at the front panel of the tester in order to open the SetUp.

16 Operation of the SetUp / changing values and settings

After opening a SetUp, you will see for example the following display:

You can now set the marker with the buttons S3 and S4.

Marker
S3
S4

If you activate the S2 button (ENTER), the marker will move in front of the value that is to be
adjusted.
With the S3 button (-) or with the S4 button (+) you can now increase, decrease or change the
value. In order to accept the changes, please activate the button S2 (ENTER).

Marker

S3
S4

S2

17 Remote control

The MotorAnalyzer can be remote-controlled.
For this purpose, the rear input for the foot switch is used. It is possible to connect a potential-free contact at this input.

The contact should be as close to the MotorAnalyzer as possible. Otherwise, disturbances could occur.

The contact serves for starting and stopping the measurement. This always refers to the test method selected via the selection switch. A remote-controlled selection of the test
methods is not possible.

18 PC program PrintCom

The PrintCom program serves for reading in test results from the tester, storing test results and printing test protocols.

There are two methods:
1. The test results are directly read in while testing (on-line method)
2. The test results stored in the tester are read in later (off-line method). This method is applied, if the MotorAnalyzer used during service at the premises of the customer and
you wish to store the test results on a PC at a later point and maybe print them out.

PrintCom indicates the test results in the form of a table. As soon as all test results have been read in, you can store the test results in an EXCEL format and print them with
EXCEL.

In order for PrintCom to be able to receive the data from the tester, NetCom must be activated in the setup of the tester.

SetUp Display
PrintCom..= yes yes : The internal result storage for temporary storage for PrintCom can be switched on or off. For
using the PC software PrintCom, a yes must be entered, here.
no : PrintCom is not being used the internal result storage is off.

Activate the SetUp button S1 at the front panel of the tester in order to open the SetUp.

For additional information, please refer to the PrintCom operating manual.

The test results are taken over into the internal storage of the tester by pressing the key S4. PrintCom will read the results out of this storage. The advantage is that PrintCom only transmits
go test results (or the results witch you want by pressing S4 ) into the protocol!

Print
The button S4 only appears after a test and only if PrintCom was activated in the SetUp. The button can be activated once.
After this, you can see the button
---
for avoiding a double storage in the protocol.

When storing surge results, PrintCom also reads in the measure values of the 3 surge curves and of the 3 reference curves. The measure values are stored in EXCEL table 2. The measure
values can also be indicated graphically via the EXCEL diagram assistant.

If the MotorAnalyzer has been switched off and on, the measure values of the surge oscillation will not be stored in the MotorAnalyzer. In order to store the values in PrintCom, the MotorAnalyzer
must remain switched on after the test until the measure values are transmitted to PrintCom.
Surgetest
-150
-100
-50
0
50
100
150
17
1
3
1
9
2
5
3
1
3
7
4
3
4
9
5
5
6
1
6
7
7
3
7
9
8
5
9
1
9
7
1
0
3
1
0
9
1
1
5
1
2
1
With PrintCom the user can generate his or her own print forms in EXCEL. You can generate forms with your own company logo, etc.

The picture shows a sample print out on a self-
designed EXCEL form. Various standard forms
are part of the delivery extent. They are the
basis for your own adaptations.

For further details, please refer to the PrintCom operating manual.

18.1 PrintCom under EXCEL97

If PrintCom is operated under EXCEL97, failures are possible. EXCEL97 has a malfunction that is removed by changing the settings of the Registry inputs of the PCs.

For this purpose, the PrintCom CD contains 2 files, which you need to activate via double-click.

The file names are:
Office97_1.reg
and
Office97_2.reg

The files can be selected on the PrintCom CD via the Explorer. Both files need to be activated via the mouse by double-clicking. On the PC screen, nothing will be indicated which
is OK.

19 Bootloader / updating the tester with a new program

19.1 General information on the Bootloader

The Bootloader serves for updating testers with a new program without having to exchange an EPROM.

The program for this tester is stored in a special programmable storage. Via a special function, the user can reprogram this storage.
This outstanding feature of the tester enables to optimize the program without having to open the tester and exchanging components.

The Bootloader software is on the CD that is part of the delivery extent. The Bootloader is a program that needs to be installed on the PC, first. For this purpose, the command
Setup.exe in the sub-directory Bootloader on the CD must be started.
After installing the Bootloader and starting the Bootloader, the monitor of the PC shows the following picture:

For transmitting a new program to the tester, first the file that is to be transmitted must be selected.

If necessary, we will send you the file that is to be transmitted via e-mail.

Attention: When programming the tester, no other program must be active on the PC. Please exit all other programs, because interrupting the programming can lead to
incorrect programming. During the programming time (max. 10 minutes), the screen saver should not start, either.

19.2 Programming

For loading the file that is to be transferred to the tester, you need to use the command from the menu bar: Datei Laden.

Now the selection window known from other programs (e.g. Word or Excel) is opened, where you can
select the file. Here you need to select the file that we have sent you via e-mail and which has been stored by
you at the respective location on your hard disk.

After this file has been selected, the transfer is ready to start.

Attention: Please select exactly the file that we have sent you.
The file name is: Motoranalyzer.hex
If you select a different file and use it to program the tester, the tester will not be functioning after this and
will have to be sent back to the factory.

Attention: During the following programming, the programming must under no circumstances be
interrupted. Otherwise the tester will not be functioning and will have to be sent back to the factory.

Attention: During the following programming, the current supply to the tester must be interrupted under no circumstances. Otherwise the tester will not be functioning and
will have to be sent back to the factory.

Attention: Before programming, please note down the version number of the old tester software. The version number is shown directly after switching on the tester.

Comparing the version number before and after programming serves to make sure that the programming has been executed correctly.

For the data transfer, the tester must be connected to the PC via a serial interface cable.

RS232 Sonden
MotorAnalyzer
Laptop

For starting the Bootloader, please activate the button Bootloader via the mouse.

Now the software checks whether it is possible to build up a connection to the tester. This action will take a few seconds.
If a firm connection can be established, the programming can be started. The display of the tester will now indicate the
following message: Remote PC ... For programming, please follow the instructions of the program Bootloader carefully.

INFORMATION on a special switching on and off procedure at the tester during the booting process:
During the process, the Bootloader will request you to switch off the tester. Now, while the tester is switched off, two
buttons on the front panel of the tester need to be activated simultaneously with two fingers: S2 and S3.
While holding the two buttons, the tester is to be switched on again. The tester is know in reading-in mode and can
receive a new program from the PC. After approximately 2 seconds, the 2 buttons can be released. The display will show
nothing. That is normal and no reason to worry. However, do not execute this procedure before the Bootloader requests
you to do so.

If you follow the commands of the program strictly, there should be no problems.

During the programming, a blue bar on the PC indicates when the programming will be completed.

After the programming has been completed, the tester automatically restarts the program. Please check now, whether the correct version of the program has been
installed. The new version number of the program should be larger than the preceding version number of the program.

Achtung: Nach der bertragung kann es eventuell zu einer Meldung im Display des Testers wie folgt kommen:

alte Datenversionsnummer update auf diese neue Datenversionsnummer

1 2
Update EEPROM

Dies ist normal. Der Tester deutet lediglich darauf hin, das nach dem Updaten des Programms nun auch neu im Programm verwendete Variablen mit sinnvollen Standardwerten
vorbesetzt werden.

Diese Meldung darf nach dem nchsten Einschalten des Testers nicht mehr erscheinen.


19.3 Connection cable between tester and PC

The tester is equipped with a 9-pole Sub-D plug. The PC can also be equipped with a 9-pole Sub-D plug or with a 25-pole Sub-D plug.

If the 9-pole connection is used at the PC, a so-called Zero Modem Cable will be used.

PC: 9-pole Sub-D Tester: 9-pole Sub-D

PC Tester
2 2 RxD

3 3 TxD

5 5 GND

PC: 25-pole Sub-D Tester: 9-pole Sub-D

PC Tester
2 2 RxD

3 3 TxD

7 5 GND

If desired, the connection cable is available, also. Article number 400125.

RS232 Sonden
MotorAnalyzer
Laptop
20 Glossary

20.1 Connection board assignment at 3-phase motors

This is the standard assignment of the connection board The motor coils would have this position

U1
U2
V1 W1
V2 W2

U1
U2
V1 W1
V2 W2

The star or delta bridges have this position on the connection board:

U1
U2
V1 W1
V2 W2
L1 L2 L3

U1
U2
V1
V2
W1
W2

U1
U2
V1 W1
V2 W2
L1 L2 L3
U1
V1
W1
U2
V2
W2

Star connection Delta connection

For testing, the MotorAnalyzer is connected to U1, V1 and W1.

20.2 Ambient temperature compensation at resistance test

The resistance of copper wire strongly depends on the temperature of the copper. An increased temperature of approx. 10 degrees results in a resistance value that is approx. 5 percent higher. In
order to be able to compare the measured resistances of a motor for example with the specifications of the manufacturer, it is necessary to have the same motor temperature. Practically, this is not
possible.
For this reason, a committee agreed that the resistances are to be indicated with a reference temperature. For Europe and many other areas with relatively low temperatures this reference
temperature is 20 degrees. In countries with higher temperatures (e.g. Brazil) the reference temperature can be 25 degrees.
Via a mathematical equation (integrated into the MotorAnalyzer) the dependence of the resistance from the temperature can be calculated exactly.
In order for the MotorAnalyzer to be able to convert the measured resistance value to the 20-degrees value, it needs to know the present stator temperature.
There are two different ways:
1. The temperature is detected via an ambient temperature sensor. It is assumed that the ambient temperature corresponds to the temperature of the stator.
2. Via a thermometer, the temperature of the stator is measured and entered into the tester. This provides the highest possible accuracy for converting the
resistance to 20 degrees. The temperature is entered in the resistance SetUp.
1Ohm - Widerstandsabweichung / Resistance Deviation
0,85
0,9
0,95
1
1,05
1,1
1,15
1
0
1
2
1
4
1
6
1
8
2
0
2
2
2
4
2
6
2
8
3
0
3
2
3
4
3
6
3
8
4
0
4
2
4
4
Temperature
R
/
O
h
m

%-Widerstandsabweichung / % Resistance Deviation
-10
-5
0
5
10
15
1
0
1
2
1
4
1
6
1
8
2
0
2
2
2
4
2
6
2
8
3
0
3
2
3
4
3
6
3
8
4
0
4
2
4
4
Temperature
%

F
e
h
l
e
r

/

%

E
r
r
o
r

Conversion of the resistance of a 1 resistance via the temperature related to 20 degrees. Fault deviation in percent of the resistance test depending on temperature related to
20 degrees.

The reference temperature (usually 20 degrees) can be entered in the Setup of the tester. During the test, the reference value is indicated here.

Ambient temperature sensor for connection at the back panel of
tester. Can be order as an option.

The measured ambient temperature is indicated here. On the basis of this temperature the resistance is converted to the reference temperature.
RS232 Sonden
MotorAnalyzer

20.3 Test time for the resistance test at inductances

When measuring the ohmic resistance at an inductance, it must be taken into consideration that, after connecting the ohmmeter, the full test current cannot flow right away. At the beginning, the
inductance reduces the current. Only after a certain period of time, the correct test current has adjusted itself. The level of the test current depends only on the voltage source inside the ohmmeter
and on the resistance value. At motors of small size (approx. up to size 132 low inductance) the delay in the current increase is not as long as at motors of high inductance. If the MotorAnalyzer is
set to Messart:Dauer, this effect is not very dramatic, because after a certain period of time a stable measure value will adjust. Experienced technicians will only use this stable value for his/her
evaluation of the resistance.
If the MotorAnalyzer is set to Messart:Einzel, this effect is of great importance, because in case of a test time that is too short surely the wrong resistance will be indicated.

Experience has shown that at completely assembled motors the charging time is even larger than at the stator. E.g. for a motor with
300HP it is not unusual if a test time of 8 seconds has to be set before the test current is stable.

If too short a test time is set, the measure value will be instable. The resistance will normally be indicated as too high, because although the
full test voltage is connected to the motor, the current is still too low.

20.4 Test current table / resistance test

In order to be able to measure even the smallest resistances with the utmost accuracy, the resistance test is executed with a test current as high as possible. It needs to be taken into consideration
that this current is unproblematic for winding resistances, but for other resistances (e.g. thermo sensors in motors) it could already be too high. The result could be for example a damaged PTC
thermistor.
The table below shows the possible test current in relation to the measured resistance and the power.

Strom / Current
0
0,2
0,4
0,6
0,8
1
1,2
1,4
1,6
0,001 0,01 0,1 1 10 100 1000 10000 1E+06
Widerstand / Resistance
A
m
p
e
r
e

Leistung / Power
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
0,001 0,01 0,1 1 10 100 1000 10000 1E+06
W
a
t
t

Attention: Only the setting in the resistance setup: Kaltleiter=ja reduces the current clearly. Under the most unfavourable conditions, only max. 2.6mA can flow.

I
t
U
I

20.5 Accuracy at resistance test

The accuracy of the resistance test is approx. 0.5% of the measured value beginning at 10m up to 100K. If the measured values are smaller or larger, the fault increases.

Theoretischer Messfehler / Theoretical Reading Error
-6,00
-4,00
-2,00
0,00
2,00
4,00
6,00
8,00
10,00
12,00
0
,
0
0
0
1
0
,
0
0
0
6
0
,
0
0
1
5
0
,
0
0
6
0
,
0
2
0
,
0
7
0
,
3
0
,
8 4 9
5
0
1
0
0
6
0
0
2
0
0
0
6
2
0
0
2
0
0
0
0
7
0
0
0
0
3
0
0
0
0
0
8
0
0
0
0
0
4
0
0
0
0
0
0
%


20.6 4-wire resistance measurement at resistance test

EXPLANATION

The picture shows a resistance Rx and 2 test probes. The test probes have 2 contact tips each, which are insulated against each other. Thus the resistance Rx has 4 connection points altogether.

At the 4-wire resistance measurement (also called Kelvin measurement), the contact resistance at the contact point between the test probes and the test object is compensated, because the contact
tip touches the test object with two separate contacts.

One contact serves for supplying the test current into the resistance and the other contact serves to pick off the voltage drop at the test object. Since the contact resistance for the test current transfer
is behind the pick-off of the voltage droop, it doesnt influence the measuring of the voltage drop.
The pre-condition of the measurement of the voltage drop is, however, a high-resistance voltage tester. Through this, the contact resistance at the contact point for the voltage test is, expressed in
percentages, in comparison to the resistance of the voltage meter, completely irrelevant.

This method is always applied if very small resistances (below approx. 1) are to be measured. This applies to measurements at motors of greater power and thus low-resistance winding resistances.

If it is possible to execute the contacting of the test object in 4-wire configuration only with great effort, it will still make sense to have the supply leads going to the test object in 4-wire configuration.
This way, the test result will not be influenced by the length of the test leads and by indeterminable contact resistances in the testing device (e.g. relays).


The picture shows the individual resistances of the simulator. Resistance 1 and 4 are the contact resistances at the contact points of the connections for the current. Resistance 2 and 3 are the contact
resistances in the voltage measuring circle.
You can see clearly that at the voltage drop test at resistance Rx, the resistances 1 and 4 dont have any effect. As described above, the interior resistance of the voltage meter must be very high in
relation to the resistances 2 and 3, so that no major measure error occurs. At the MotorAnalyzer, this is the case.

For connecting the test object in 4-wire configuration, SCHLEICH offers a variety of contacting devices.
Below please find pictures of Kelvin clamps for connecting wires and bolts and Kelvin test probes for testing armatures.

Kelvin clamps Kelvin test probes 4-wire resistance measurement to the test probe tip (should be used like this at the PE test)

U-Sense
Strom


If no Kelvin clamps or Kelvin test probes are available, there are various temporary solutions for testing at the stator:

Temporary solution 1 - where at least the resistances of the measure leads are compensated

U V W Frame High Voltage
Krper
R
PE

Temporary solution 2 - this variant is a fully adequate 4-wire measurement where the resistances of the measure leads and of the contact points are compensated

U V W Frame
+HV
High Voltage
Krper
R
PE

Of course, this solution can also be used for 3-phase test objects.

If you test at motors with terminal board bridges, at low-resistance motors, the brigdes must be firmly screwed down. Otherwise there would be contact resistances that influence the measure
value.
20.7 Resistance test at armatures

Since at armatures more than one coil resistance is measured, the resistance test is difficult.

At an armature with 8 lamellas, the picture gives you a simplified impression of the problem. Each lamella has a contact resistance to the winding the so-
called welding resistance. This resistance is created at the welding point (or soldering point, squeezing point between winding and lamella). The actual
winding is connected to the welding resistance.

If you now measure the resistance between two adjacent lamellas, you will get a measure value coming from 2 (sometimes even unequal welding
resistances) and the coil between the two lamellas and the remaining parallel winding parallel.

The MotorAnalyzer thus does not directly show only one coil resistance, but always the combinations of
resistances.
When comparing the resistances between the lamellas, for the relative comparison of the values,
however, this is not very important.
Except if the individual coils have varying winding numbers or there is an equalizing winding.
For comparing the resistances it is thus absolutely necessary to be familiar with the design of the winding.
If not, it is possible that wrong conclusions are drawn from the test results.

Another measure error can be that it is assumed that the resistance between 2 lamellas is half as large as between the 1st and the 3rd lamella, etc. The schematics below are supposed to
explain this mistake. For better understanding it is assumed that the coil resistance is 1 Ohm and the welding resistance is 0 Ohm.

Rmeas= 0.875 Rmeas=1.5 Rmeas=2

It can be seen clearly that, owing to the series connection and the parallel connection of the winding components the correlation doubled distance of lamellas = doubled resistance doesnt exist.


20.8 Surge test

In contrast to standard insulation test methods, the surge test offers an insulation test from winding to winding, from coil to coil, from group to group, from phase to phase and,
under certain preconditions, also from the winding to the frame.
It can be tested at individual coils or phases or at the connected stator.
The high voltage or insulation resistance test can only find insulation faults to the frame and at unconnected motors from phase to phase. The surge test can also find faults and
connected windings.

In order to be able to find continuously existent insulation faults (shorts) within a winding, a surge test can also be executed with low voltage. For this purpose, the
MotorAnalyzer is used, which generates surge pulses with a voltage level of 12V.

For also being able to find voltage-related insulation faults within a winding branch, e.g. from winding to winding, a voltage difference as large as possible from winding to
winding, between the coil groups or the phases needs to be generated.
In order to reach high voltage differences of several 1000V, SCHLEICH testers MTC3 or MTC4-WIN are to be used. For this type of test, the MotorAnalyzer is not suitable.

Principle of surge test
A voltage impulse is connected to the winding to be tested. This impulse is connected almost abruptly. This is why the connection of the voltage is also defined as surge
voltage. Since the surge voltage is connected to the winding only for a short period of time, the winding will now be damaged permanently. At the standard high voltage test,
however, there could be a damage owing to a a connection of the high voltage for too long a period of time. In praxis, insulation faults normally develop only slowly, under the
continuous strain of the motor, from a minor fault a permanent fault.

The schematic sketch shows the function of the test. The capacitor and the switch are inside the MotorAnalyzer, the inductance is the coil to be tested.

The impulse is generated by very fast parallel switching of a loaded capacitor to the winding to be tested. After the capacitor has been connected, the
stored energy is discharged into the inductivity and then back into the capacitor, etc. Attenuation losses, etc. result in a sinusoidal reduced sympathetic
oscillation. It has a frequency that is characteristic for the inductivity to be tested and a typical amplitude characteristic.

This is what the surge impulse could look like at a faultless test object.

These could be oscillations of test objects with faults.

The surge test is a comparative test.
Always two or three oscillations are compared with each other or with a good reference stator stored before.

When comparing the phases with each other, it is possible that industrially manufactured 3-phase machines show deviations of the oscillations, although the stator has no
faults. The reason for this, at these motors, is the mechanically unsymmetrical position of the phases in the slots.

Below please find a list of typical faults, which can be measured in both start and delta connection. The pictures show typical faults and the resulting test oscillation.

1. Stator go
The two oscillations differ not at all or only slightly.

2. Ground short circuit | Test methods: Surge test High voltage test

3. Ground short circuit | Test methods: Surge test High voltage test (if not connected) Resistance test with limitations
Both oscillations differ strongly and have no even sinusoidal form.

4. Open circuit | Test methods: Surge test Resistance test


5. Short circuit between the coils of one phase | Test methods: Surge test Resistance test with limitations
The first oscillation is good, the second oscillation is strongly reduced.

6. Short circuit between the windings of one coil | Test method: Surge test


7. Short circuit between windings that only shows by lightning discharge

This test can only be executed with the high voltage test of the MotorAnalyzer to ground. It can not be executed within the coil, because the test voltage is too low.

For this purpose, SCHLEICH testers MTC3 or MTC4-WIN need to be used.


20.9 Explanation on the interpretation of results at surge tests

If a fault is detected during the surge test, it is often important, to locate the faulty phase. Especially in case of star connections, this not as easy as it might seem.

Star connection

The below drawing is to describe this:

U
V W
1. Messung
3. Messung
2. Messung

Assuming that the oscillations of all 3 phases are normally equal, a fault in phase U will result in the following measurements:

The first measurement and the third measurement have the same oscillation
The second measurement has a deviating oscillation

Now, the faulty phase is not in the deviating oscillation, but in the two equal oscillations!

1st measurement: U-V
2nd measurement: V-W
3rd measurement: U-W

Equal oscillations : 1st measurement: U-V and 3rd measurement U-W
Deviating oscillation : 2nd measurement: V-W

The simple rule is that the fault in a star connection is always located in the phase of the which the letter appears in both measurements at the same time.
In our example this is the phase U, because this occurs both in the first and in the third measurement.
Delta connecion

The below drawing is to describe this:
V W
1. Messung
3. Messung
2. Messung
U

Assuming that the oscillations of all 3 phases are normally equal, a fault in phase U will result in the following measurements:

The second measurement and the third measurement have the same oscillation
The first measurement has a deviating oscillation

Now, the faulty phase is not in the deviating oscillation!

1st measurement: U-V
2nd measurement: V-W
3rd measurement: U-W

Equal oscillations : 2nd measurement: V-W and 3rd measurement U-W
Deviating oscillation : 1st measurement: U-V

The simple rule is that the fault in a delta connection is always located in the phase that shows a deviation in the oscillation.

20.10 Surge test for detecting a twisted phase

This picture shows the usual layout of the phases. In case of a twisted phase, a fault would look for example like this.

In order to measure a fault like this, you can execute the following three measurements with the 1-phase surge test. (See chapter 5.3, bottom picture, 1-phase test)

1st test: connect 2 phases and do a surge test through these two phases 1-phase with reference storage.

The test result of this test will be stored in the reference storage of the tester.

2nd test: connect 2 other phases and do a surge test through these two phases. The result will be compared to the result, which has before been stored as reference.

At this test, the example shown on the picture would have the same oscillation as the 1st test.

3rd test: connect 2 other phases and do a surge test through these two phases. The result will be compared to the result, which has before been stored as reference.

At this test, the example shown on the picture would have a different oscillation compared to the 1st test (and 2nd test).

Normally, all 3 tests should have the same result. If the result is completely different, you have a completely twisted phase.

The fault is at the phase that is involved in 2 tests. In this example, this would thus be the phase in the middle. This also means that there are two equal and one unequal surge curve (compared
to the two equal curves). The phase involved in both equal tests is the twisted phase!
In the unequal test, the twisted phase is not involved (please refer to the 3 test pictures).

20.11 Insulation resistance test and PI

The high voltage or insulation resistance test can also be performed following the step voltage method: the test voltage is automatically increased in 10 steps from 0V to the programmed value. This
method is used for detecting locally limited insulation faults. The high electric load of the weak point occurs especially in case of higher voltages. A fault is indicated by the reduction of the insulation
resistance in case of higher voltages. The evaluation is supported by the graphic display of the insulation resistance in the resistance/time diagram.

Tester
Good isolator without weak points
Tester
Isolator with a weak point
therefore the load is concentrated
to this weak point

The PI is an alignment of the movable charge carriers in the electric field. At the PI test, it is connected from outside via a high voltage for 10 minutes. At good motors, the PI is normally 1.5
5. Higher values are even better. Lower values are a sign of bad insulation.
ATTENTION: The PI test must be performed very sensitively - otherwise you get incorrect results. The test leads to the motor should be as far away from each other as possible and the test leads
must under no circumstances be touched during the test. It is best to use the special test leads for the insulation resistance test.
Tester
+
-
+ -
+
-
+

-
+

-
+
-
+

-
+ -
+
-
Insulation without polarization
Tester
+

-
+

-
+

-
+

-
+

-
+

-
+

-
+

-
+

-
Isolator with polarization
because no voltage is connected

20.12 Explanations on the high voltage test

Electromotors are usually highly capacitive. The highest capacity is between the winding and the frame. There is also a smaller capacity between the windings.
You can basically say: the larger the motor, the larger the capacity.

Depending on between which points it is currently tested, the capacities are loaded, during the test, to the level of the test voltage. At the high voltage test with AC,
especially the high capacities of the motors result in a high test current, which consists of the capacitive current and the current through the insulation resistance.
At the high voltage test with CD (like at the MotorAnalyzer), the capacitive current is only important for connecting or adjusting the test voltage. After the capacitor has
been charged, only the usually very low current flows through the insulation resistance.

During the test it is possible that parts, which are not involved in the test, are charged also. This means that for example a ground
short circuit test between U and the frame could charge the other components to a certain extent, also.
Especially for PTC-resistors and KTY-sensors this could be critical. The charging could damage theses sensors.

Before testing, the leads of these sensors therefore always need to be shorted with each other. If necessary, they can also be directly
connected to the casing.

ATTENTION! After the test, the test object therefore must be discharged in all parts. Otherwise, the operator could suffer an electric shock when touching
the test object.

ATTENTION! Touching the measure leads and the tester at the same time, could also cause a weak (but harmless) discharge. Although the measure leads
are insulated, their insulation resistance is limited. The operator could charge and discharge, also.
Tester

Further detailed information on the high voltage test

Theoretically, the high voltage test is thus executed at an RC element. The RC element is the idealized form of the conditions at the test object.
Why?
The test object has an insulation resistance between the two test points: the resistance Riso. With some 100Mohm and more, this resistance is usually very high. In addition, the
test object has a capacity between the two test points. This capacity develops either between the windings to be tested or from winding to frame. Between the windings it is
usually smaller than from winding to frame. Capacities are produced between insulated metal surfaces. The larger the surface or the shorter the distance of the metal surfaces,
the larger the capacity. In stators, the windings are one surface and the casing is the other surface. Large stators have large surfaces and thus large capacities.

If the high voltage test is executed with AC, a high capacitive recharge current is flowing in the stator (RC element). Very often, this capacitive recharge current is much higher
than the leakage current through the ohmic resistance Riso (being extremely high-ohmic). I.e., owing to the capacitor the continuously flowing recharge current, at the high
voltage test with AC through the capacitor, strongly overlaps the fault current that is actually to be tested with the resistance.
The capacitive recharge current is no fault current, but a current based on physical laws. It is always existent and is no quality characteristic of a stator. Certainly, the current
must not be too high, but is gives no reliable information about the quality of the insulation.

Via the high voltage test with DC (direct voltage), the recharge current can be avoided. Weak fault effects there become more evident.
The schematics of the insulation system of the motor (see below) serves for a better understanding of the conditions at the insulation resistance test. On the left side of the
schematics, you can see a sketch of the motor. The motor consists of windings and the insulation system to the casing. The schematics of the insulation system consist of a
resistance and a capacitor. As described above, the capacity derives form the physical and mechanical conditions at the motor. The resistance, which is within a range of several
100 MegaOhms, is an indicator of the insulation quality.

C
Riso

The picture below indicates the electric test conditions during the insulation resistance test with DC.

On the left side of the picture you can find the schematics. The test voltage is connected to the capacitor and to the resistor. At the upper right of the graphics, you can see the
voltage curve. The voltage is increased in the form of a ramp (the high voltage is, for example, increased via the potentiometer at the MotorAnalyzer slowly and evenly. As soon
as the test voltage has been adjusted to the desired value, it stays at the same level.

Below the voltage curve, you can see the current curves during the test.

The first current curve indicates the current in the capacitor. It shows that, while the voltage is increased, the loading current in the capacitor stays at the same level. As soon as
the voltage is at a constant level, the loading current in the capacitor goes back to zero.

The second current curve indicates the current in the insulation resistance. It shows that, while the voltage is increased, the current in the resistance increases continuously,
also. As soon as the voltage doesnt change any more, the current stays at a constant level.

The third current curve indicates the sum of both currents. This current curve is measured and indicated during the insulation resistance test at the motor. As described above, it
consists of the two partial currents of capacitor and resistance. Of course, the schematics only offer a theoretical view. In praxis, however, the current curve is very similar.

t
U, I
U
I
C
C
Riso
U
DC
I
DC
I
C
I
R
t
I
R
t
I
DC
t

At the high voltage test with alternating voltage, the current is usually in the range of several mA and at large machines up to several 100mA.
At the high voltage test with DC, the currents are considerably smaller.
If you have a motor with a bad insulation resistance of 2M, at 2000V test voltage a current of 1mA is flowing.
If you have a motor with a good insulation resistance of 200M, at 2000V test voltage a current of 0,01mA (10A) is flowing.

21 Digital high voltage tester GLP1e-HV or high-voltage tester with analog display GLP1a-HV

SCHLEICHs high voltage tester GLP1e-HV is an ideal supplement for the MotorAnalyzer.

The high voltage tester GLP1e-HV serves for testing the electric insulation resistance and electric strength (air clearance and
creepage distance) at electronic components and modules. These tests are done in accordance with various national and
international regulations.
The GLP1-HV is well suited for fast and uncomplicated manual testing in production.
The device supplies a manually adjustable sinusoidal high voltage of 0 up to approx. 5500V AC.
As guide value for the detection of the test voltage the following rule applies: 2*U
n
+1000V (U
n
= nominal voltage).
With max. 5500V it thus delivers not only the test voltages for the routine tests determined in the standards, it is ideally suited
for type tests and laboratory tests with higher voltages.

The high voltage is usually connected to the test object via high voltage test pistols.
There are three different proceedings for the test:

1
st
Test with continuous voltage (Man)
The high voltage is switched on at the GLP1-HV and stays on until all tests are completed.
Advantage: with the test pistols you can quickly go from test point to test point, without having to re-start the GLP1-HV every
time. However, the over-current release stays active.
Disadvantage: the test is not executed with the minimum time requested by standards. The operator can determine the test time
as desired. A further disadvantage is that the test pistols are approached to the test object under voltage and also removed
under voltage. It is possible that considerable voltage peaks occur, which could damage the test object.

2
nd
Test with connected voltage (Auto)
The high voltage is connected to the test object only after the test pistols have been connected to the test object and before they are removed the voltage is switched off.
Disadvantage: the voltage needs to be switched on via an additional foot switch or via a test pistol with integrated start switch.
Advantage: with the time pre-setting in the GLP1-HV, tests are done exactly according to standards.

3
rd
Test with burning function
For burning out test objects

Test objects are damaged less, because the high voltage is connected with a semiconductor switch at zero crossing in order to avoid voltage peaks.
Since, after switching off the test voltage, the test pistols still contact the test object for a short time, this automatically leads to a discharge of the test object via the secondary winding of the high
voltage transformer.
In the automatic mode, it is possible that, during the test, a minimum and maximum voltage check are activated. If the test voltage is too high, the GLP1e-HV switches off automatically. If the test
voltage is too low, there will be an acoustical signal.
For testing electro motors in series production, it is in addition possible to activate a minimum current test. At electro motors, owing to the capacity of the test object, there is always a current flowing
when the voltage is connected. This current can be used as feed control. If the minimum current isnt flowing, it is much likely that no high voltage is connected to the test object. The result is that the
test time is also not running, because it is only enabled when the minimum current is flowing.

All these advantages offer a very high test safety. These monitoring functions, which can be activated, enable also an operator who is lacking practice to execute the tests reliably and process-safe.

The large, bright and well-readable display for voltage, current and time contributes to the comfortable working features of the GLP1e-HV. They can be read even from a far distance.

Since the standard high voltage tester is equipped with a serial RS232-interface, it is possible to connect a printer, a PC or a PLC. Simple control commands via the serial interface allow a complete
remote control of the GLP1e-HV. This allows the user to remote-control the tester himself or apply our software NetCom-XI or PrintCom.

For an optimum integration of the tester into a test station, all necessary connections for safety contacts, warning lamps, control inputs and message outputs are available at the back of the tester.
The high voltage can also be made available at the back panel.
PC
analog
RS485
SPS IO
RS232

TECHNICAL DATA of GLP1e-HV
....................................................................................................................................................................................................................................................................................
High voltage test AC Voltage range 0 ... 5500VAC / switching-on of the test voltage at zero crossing in order to avoid voltage peaks
Current / power max. 100mA / min. 200mA and 500VA according to VDE- IEC-regulations in case of short circuit
Current limit value 0.1mA ... 99.9mA and burning without current limitation / release time <30ms
Monitoring minimum current, minimum voltage and maximum voltage monitoring, e.g. for automatic tests
Test time 0.1 sec. ... 160 sec. and without time limit
Ramp acceleration ramp with pre-settable ramp time (option)
.....................................................................................................................................................................................................................................................................................
Operation Mains switch key switch for the protection against unauthorized usage
High voltage On / Off illuminated button on the front panel, foot switch, start switch inside test pistol
Safety according to VDE0104 / safety switch, test cover, Emergency-Stop and/or warning lamp
Display well-readable 2-line, 16-digit display for high voltage, current and test time
resolution: high voltage: 10V - current: 0.1mA - time: 0.1sec / optical and acoustical error message
.....................................................................................................................................................................................................................................................................................
Interfaces Outputs test in process, GO, disruptive breakdown, NO GO, high voltage on, high voltage off (e.g. for a PLC)
Inputs safety contact (test case or protection doors), start, stop, foot switch, start contact in test pistol, Emergency-Stop
Serial 1 (RS232) Remote control with complete control over the tester (e.g. with PC or PLC) or for the printer
Analog outputs 2 * 0...10VDC-outputs in proportion to the high voltage and to the current (option)
Analog inputs 2 * 0...10VDC-inputs in proportion to the high voltage and to the release current limit (option)
.....................................................................................................................................................................................................................................................................................
Device data Mains supply 230V AC (115V) +/- 10% / 49Hz...61Hz
Dimensions / weight 236mm * 179mm * 320mm (W * H * D) / approx. 16kg / operating temperature 10C ... 50C
Enclosure types table-top device or 19"-unit 4 height modules / 42 depth modules with the respective attachment accessories / OEM-version
.....................................................................................................................................................................................................................................................................................
PC-software NetCom Xi Operating system WINDOWS

Standard function single tests, test programs with test steps, long-term tests with line recorder function, network operation
Storage ACCESS-database and export of measure values in EXCEL
- and ASCII-format
PC-software PrintCom Operating system WINDOWS

Storage EXCEL
-table, generation of protocols of various designs

....................................................................................................................................................................................................................................................................................

For further technical details please refer to our homepage.

Let us submit our detailed offer including extensive accessories.

We also supply high voltage testers with up to 30000V and a test current of up to 1A.


Konformittserklrung

Die Unterzeichner erklren im Namen der Firma

Schleich Antriebs- und Steuerungstechnik GmbH

An der Schleuse 11
D-58675 Hemer

dass der Tester

MotorAnalyzer

auf den sich diese Erklrung bezieht
die nachstehenden EG-Richtlinien
(einschlielich aller zutreffenden nderungen)
erfllt

73/23/EEC Niederspannungsrichtlinie
89/556/EEC Elektromagnetische Vertrglichkeit

und das die nachfolgenden Normen zur
Anwendung gelangt sind.

IEC/EN61010-1 Sicherheitsbestimmungen fr elektrische Mess-, Steuer-, Regel- und Laborgerte
IEC/EN61326-1 EMV-Anforderungen / Elektrische Betriebsmittel fr Leittechnik und Laboreinsatz
EN61000-4-2 EMV / Strfestigkeit gegen Entladung
EN61000-4-3 EMV / Strfestigkeit gegen hochfrequente elektromagnetische Felder
EN61000-4-4 EMV / Strfestigkeit gegen Burst
EN61000-4-5 EMV / Strfestigkeit gegen Surge
EN61000-4-6 EMV / Strfestigkeit gegen leitungsgefhrte induzierte hochfrequente Felder
EN61000-4-11 EMV / Strfestigkeit gegen Netzstrungen

Hemer, 1.6.2003

Dipl.Ing. M. Lahrmann Karl-Dieter Schleich
Geschftsleitung Geschftsleitung

Declaration of Conformity

The undersigned declare on behalf of


An der Schleuse 11
D-58675 Hemer

That the testers

MotorAnalyzer

to which this declaration relates
(serial number specified on the product)
are in compliance with the below mentioned
EEC Directives (including all amendments)

73/23/EEC Low Voltage Directive
89/556/EEC Electromagnetic compatibility

and that following standards have been applied

IEC/EN61010-1
IEC/EN61326-1
EN61000-4-2
EN61000-4-3
EN61000-4-4
EN61000-4-5
EN61000-4-6
EN61000-4-11

Hemer, 1.6.2003

Geschftsleitung Geschftsleitung

Dclaration de Conformit

Les soussigns dclarent au nom de


An der Schleuse 11
D-58675 Hemer

que le produit

MotorAnalyzer

a quel se rfr cette dclaration
(numro de srie indiqu sur le produit)
est en conformit aux directives CE cites
ci-aprs (amendements inclus)

73/23/EEC Directive basse tension
89/556/EEC Compatibilit lectromagntique

et que les normes suivantes on t appliques

IEC/EN61010-1
IEC/EN61326-1
EN61000-4-2
EN61000-4-3
EN61000-4-4
EN61000-4-5
EN61000-4-6
EN61000-4-11

Hemer, 1.6.2003

General Manager General Manager

Dichiarazione di Conformita

I sottoscritti dichiarano in nome e per conto della ditta


An der Schleuse 11
D-58675 Hemer

che l'apparecchio di prova

MotorAnalyzer

al quale questa dichiarazione si riferisce,
soddisfa le direttive CE elencate qui di seguito
(comprese tutte le modifiche che le riguardano)

73/23/EEC Direttiva per la Bassa Tensione
89 e ZV al /556/EEC Compatibilit Elettromagnetica

e che si fatto uso delle seguenti norme:

EN 55022 Emissione disturbi
IEC/EN61010-1 Disposizioni per la sicurezza di apparecchi elettrici di misura,
di comando, di regolazione e da laboratorio
IEC/EN61326-1 EMC / Esigenze e requisiti / Mezzi desercizio elettrici per il controllo
e la conduzione di processi e per luso di laboratorio
EN61000-4-2 EMC / Immunit ai disturbi generati da scariche elettrostatiche
EN61000-4-3 EMC / Immunit ai disturbi generati da campi elettromagnetici ad alta frequenza
EN61000-4-4 EMC / Immunit ai disturbi generati da Burst
EN61000-4-5 EMC / Immunit ai disturbi generati da Surge
EN61000-4-6 EMC / Immunit ai disturbi indotti generati da campi ad alta frequenza
EN61000-4-11 EMC / Immunit ai disturbi di rete

Hemer, 1.6.2003

Direttore commerciale Direttore commerciale

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