A Review of the ALL-TEST IV PRO 2000 and SKF/Baker AWA II

Howard W Penrose, Ph.D., CMRP

Vice President, Engineering and Reliability Services
Dreisilker Electric Motors, Inc.
Abstract: The importance of understanding the
capabilities and limitations of the technologies for testing
electric machines cannot be understated.
Modern
methods include both high and low voltage tests including
insulation to ground, turn impulse testing, and motor
circuit analysis. In this paper we will review several
examples of the capabilities and limitations of both PD
Surge, using an SKF Baker AWA II-6kV (AWA), and a
Motor Circuit Analyzer, the ALL-TEST IV PRO 2000
(AT4).
The comparison will include time to test,
evaluation of the scope of test, and several examples of
missed findings where other methods were able to detect
the fault. In each case, the actual issues, if any, were
unknown prior to the performance of each test.

by Dreisilker Engineering to take the

opportunity to review the AT4 and the AWA
without representatives of either vendor
participating. The results were interesting and
provided important information on the accuracy
of both technologies both in comparison and in
capability.

Note: We are looking to evaluate other test instruments

such as the PdMA as part of this study. If you wish to
lend us your PdMA tester for 3-4 weeks, please contact
Dr. Penrose at hpenrose@dreisilker.com.

The tests were performed on relatively small

electric motors of about ten horsepower,
480Vac, through to 19,000 horsepower, 13.2kV,
including through over 1,000 feet of run. Each
case was introduced into real world conditions
without prior knowledge of the actual conditions
of the machines. One 8000 horsepower electric
motor made for an interesting case study and
will be included in this paper.

Introduction
For well over a century the primary methods for
electricians to evaluate machines have been
limited to insulation to ground testing,
continuity and other similar tests. During the
1980s advanced test methods came onto the
market that utilized both high voltage and low
voltage methods to determine the condition of
machines in the field.
One method is based upon the surge comparison
methodology which utilizes a tank circuit and a
series of fast rise time pulses sent to a winding.
The other utilizes very low voltage levels and
higher frequencies along with bridge circuits to
evaluate the condition of the windings. The high
voltage test is exploring for insulation weakness
while the low voltage test is exploring for
insulation condition.
In both cases, the
technologies require a path to detect faults.
During several weeks at the end of June, 2010,
and the beginning of July, 2010, Dreisilker
Electric Motors, Inc. was requested to review the
capabilities of the AWA II-6kV system which
weighs approximately 40 lbs. It was determined

The live tests can be viewed on the MotorDoc

channel
of
http://www.YouTube.com
(http://www.youtube.com/user/motordoc).

The results of this paper led the investigators to

a greater understanding as to the need for
training and experience in each of the
technologies they use.
Inexperienced
technicians tend to rely too much on exact
results which can end with unfortunate
conclusions.
It will also be noted that several of the case
studies presented indicate the failure of the
technology(s) to detect specific faults within
their advertised capability. ANY technology
that claims that this proves their technology
superior had obviously not been subjected to the
rigors of this analysis and cannot make such
claims. In effect, buyer beware of such tactics
(and we would be happy to put them through the
same rigors and comparisons). It is noted by the
investigators that each of the technologies
evaluated in this paper have performed
admirably in the field for over two decades.

Overheated Windings
During the testing that was being performed, a
great number of motors, with a few of them
shown in the YouTube videos, were tested both
assembled and disassembled. The purpose of
this paper is to identify where things were
missed and to evaluate the reasons why.
The first evaluation that was missed was a
submersible pump. Both the AT4 and AWA
were used with the full range of both
instruments (abbreviated for YouTube, the PI
was not performed with the AWA, just the DA).
The AWA was set for resistance, 500Vdc
insulation resistance and DA, a high potential
test of 2000 Vdc, and a surge test at 2000 Volts.
The value for the high potential and surge tests
should have been:
Eq. 1: DC High Potential (used winding)

( 2( 480V ) + 1000V ) * 1.7 * .65 = 2,166V

Eq. 2: Surge Test (new winding)

( 2( 480) + 1000V ) = 1,960V

The values used were the default values of the
AWA. The submersible was tested with the
default 480 Vac machine values built into the
AWA, including the Dielectric Absorption
(DA). The findings can be found as Attachment
A of this white paper.
The AT4 was also utilized and all of the tests
performed were satisfactory. The motor was
disassembled and the stator inspected. The AT4
and AWA had detected rather low insulation
readings which changed as the leads were
moved.
The submersible had been installed and the cable
fouled and damaged. It was then energized.
Upon disassembly of the pump, it was
determined that the winding had overheated as
the ties broke on the windings. The insulation,
in general, looked to be in good condition other
than the overheating (Figure 1). The low

insulation resistance related to the leads was due

to the insulation on the leads deteriorating. The
low insulation resistance detected a potential
problem; the additional work identified the
issue.
Figure 1: Overheated Winding

The conclusion was that experience is still

required even while using advanced testing
equipment. Without the experience to hunt
down the cause for the odd insulation resistance
readings, the unit might have passed and been
put back into service as both technologies passed
the winding based upon automated (software)
analysis. Understanding the presented data
allowed the technician to focus in on the fault.
8000 hp 13.2 kV Machine
Another project involved reviewing the
condition of two large 13.2 kV machines. One
at 19,000 horsepower synchronous and one
8,000 horsepower induction that had tripped off
line. The unit available for initial testing was
the 6kV AWA unit at close to 40 pounds and
requiring a 100 foot extension cord. The other
unit was the ALL-TEST IV PRO 2000.
Table 1: AT4 Pro 19000hp Data
T1-T2
T1-T3
T2-T3
0.0125
0.0139
0.0134
Resistance
3
3
3
Impedance
0
0
0
Inductance
44
44
44
Fi
-48
-47
-47
I/F
The AT4 was used from the disconnect
approximately 250 yards away with results

showing in Table 1 for the 19,000 horsepower

motor. The AWA was used with the resistance,
insulation resistance, and polarization index
being used from the disconnect. It required
disconnection at the motor (the lightning
arrestors and surge arrestors were disconnected
for all testing) to perform the high potential test
and surge test.
Figure 2: Surge Test 19000 hp

The motor was pulled from service and

disassembled for evaluation. It was immediately
apparent that one winding had blown and had
impacted the coil immediately across. It was
also apparent that the sole reason why the fault
was detected with insulation resistance and
capacitance testing was carbon dust and
conductive contaminants on the surface of the
conductors. If there had been any break, the
fault would not have been detected even with
four wire Kelvin technology.
Figure 3: Actual Fault Image

A phase to phase insulation resistance test was

also performed with the neutral open and a
phase to phase capacitance test was performed
with the ATIV. Based upon the success of all of
the testing, it was determined that this motor
could be started, and was, successfully.
The 8000hp machine was evaluated at the
motor. The surge test passed at 6,000 Volts, the
insulation resistance and PI tests passed, the step
voltage high potential test passed, and the ATIV
test passed (Table 2).
Table 2: ATIV Test 8000 hp
T1-T2
T1-T3
T2-T3
0.1484
0.1486
0.1504
Resistance
164
168
172
Impedance
32
33
34
Inductance
88
88
88
Fi
-49
-49
-49
I/F
The capacitance readings using the ATIV
identified an issue and the insulation resistance
test between A phase and B phase tripped on
overcurrent at 3250 Vdc. As only these tests
identified a fault, a second high voltage
insulation resistance test was performed with a
different meter. It also failed at over 3200 Vdc.

Figure 4: Image Inside Faulted Coil

During the investigation, it was noted that the

machine and coil passed a surge test at 22,700
V. The fault was in the first two turns of the
first coil of Phase A. What surprised the
investigators was that resistance, AWA, surge,
and AT4 should have identified this fault even at
the test voltages used. It was also noted that
when the carbon and contaminants were brushed
away from the coils that the insulation resistance
and capacitance between phases was excellent.
Single Phased Motor
During a field analysis of an electronic soft start,
an electric motor was found to have a good
insulation to ground, good ohm readings and
continuity, and passed a surge comparison test.
The AT4 was used and the results showed as in
Table 3, which shows a turn to turn short and
overheated windings.
Table 3: AT4 Blower Motor Evaluation
T1-T2
T1-T3
T2-T3
4.0996
4.1019
4.0986
Resistance
165
163
169
Impedance
34
32
33
Inductance
83
86
86
Fi
-46
-49
-49
I/F
Figure 5: Stator Condition

As shown in Figure 5, one coil group was

burned in the motor.
Conclusion
As noted in Electrical Motor Diagnostics: 2nd
Edition, no one test method can be relied upon

to detect all faults. There is also a high risk of

missing faults if the operator does not have a full
understanding of the technologies used and
equipment that is being tested. It is equally
important to note when a single component of a
suite of tests performed identifies a potential
fault that additional investigation is necessary.
The experienced technician needs to use his
senses and knowledge as a tool as much as the
test equipment available. This is particularly
important as 20% or more of electric machines
are pulled for repair or replacement that have no
problems to begin with. Even worse is when
parts are swapped in an effort to plug and play
a solution to a problem when equipment is
down. These issues occur a majority of the time,
especially when the technician does not trust
himself or his technology.
Bibliography
Penrose, Howard W, Ph.D., CMRP, Electrical
Motor Diagnostics: 2nd Edition, SUCCESS by
DESIGN, Connecticut, 2008.
About the Author
Howard W Penrose, Ph.D., CMRP is the Vice
President of Engineering and Reliability
Services for Dreisilker, the Web Editor-in-Chief
of the IEEE Dielectrics and Electrical Insulation
Society, the Director of Membership for the
Society for Maintenance and Reliability
Professionals (SMRP) and serves on the Board
of Directors for the Autism Society of Illinois.
He has won five consecutive UAW and General
Motors People Make Quality Happen Awards
(2005-2009)
for
energy,
conservation,
production, and motor management programs
developed for GM facilities globally and is an
SMRP Certified Maintenance and Reliability
Professional (CMRP). Dr. Penrose is the author
of the Axiom Business Book Award (2008
Bronze and 2009 Bronze) winning Physical
Asset Management for the Executive (Caution:
Do Not Read This If You Are on an Airplane),
and the 2008 Foreword Book of the Year
Finalist textbook, Electrical Motor Diagnostics:
2nd Edition. Dr. Penrose may be contacted by
email at hpenrose@dreisilker.com.

Nameplate Information
Location
DEM Winding
Model
Serial Number
Volts-Rating
Amps-Rating
Insulation
RPM
Frame
LR Code
NEMA Design
NEMA nom eff
Manuf's Type
Description

460
32
F
1760

b
0

Motor ID O275467
Building
Incoming
Manufacturer
FAIRBANKS
MORSE
HP/KW
25
Volts-Operating
460
Amps-Operating 32
Enclosure
SUB
Service Factor
1.15
Freq-Hz
60
LR Amps
0
Max Amb C
40
Duty Cycle
cont
Manuf Dt Cd
Place holder MotorID. After adding
valid motors, delete this one

Nameplate Information
Location
DEM Winding
Model
Serial Number
Volts-Rating
Amps-Rating
Insulation
RPM
Frame
LR Code
NEMA Design
NEMA nom eff
Manuf's Type
Description

460
32
F
1760

b
0

Application Information
Test ID
480V w/Rotor<100HP
StepV
Tested By
Room #
Location
DEM Winding
Use
Vert/Horiz
Starts/24Hrs
Install Dt
Volts 1
0.0
Volts 2
0.0
Volts 3
0.0
Tester Type
AWA4_6kV_4Wire
Tester ID
10226
Cal Date
09/01/2009

Motor ID O275467
Building
Incoming
Manufacturer
FAIRBANKS
MORSE
HP/KW
25
Volts-Operating
460
Amps-Operating 32
Enclosure
SUB
Service Factor
1.15
Freq-Hz
60
LR Amps
0
Max Amb C
40
Duty Cycle
cont
Manuf Dt Cd
Place holder MotorID. After adding
valid motors, delete this one
Test Date/Time 6/29/2010 12:13:14 PM
Repair/Job #
Tested For
MCC
Building
% Load
Starter
Rewind Dt
Basic Dt
Amps 1
Amps 2
Amps 3
Tester SN
PP30 SN
Next Cal Date

Incoming

0.0
0.0
0.0
10226
0
09/01/2010

Nameplate Information
Location
DEM Winding
Model
Serial Number
Volts-Rating
Amps-Rating
Insulation
RPM
Frame
LR Code
NEMA Design
NEMA nom eff
Manuf's Type
Description

Results Summary
Test ID:
Tested By
Room #
Location
Temp Status
Temp
Resist Status
L1-L2 (Ohms)
L2-L3 (Ohms)
L3-L1 (Ohms)
Max Delta R %
Coil 1 (Ohms)
Coil 2 (Ohms)
Coil 3 (Ohms)
Megohm Status
Volts (V)
Current(A)
Resist (Mohm)

460
32
F
1760

b
0

480V w/Rotor<100HP
StepV

DEM Winding
Tested
26.7C 80.0F
PASS
0.505 Corr: 0.501
0.505 Corr: 0.501
0.504 Corr: 0.501
0.083%
0.252 Corr: 0.251
0.253 Corr: 0.251
0.252 Corr: 0.251
PASS
500
2.50
200 At 40C 79

Motor ID O275467
Building
Incoming
Manufacturer
FAIRBANKS
MORSE
HP/KW
25
Volts-Operating
460
Amps-Operating 32
Enclosure
SUB
Service Factor
1.15
Freq-Hz
60
LR Amps
0
Max Amb C
40
Duty Cycle
cont
Manuf Dt Cd
Place holder MotorID. After adding
valid motors, delete this one
Test Date/Time 6/29/2010 12:13:14 PM
Repair/Job #
Tested For
MCC
Building
PI Status
Volts (V)
DA Ratio
PI Ratio
HiPot
Volts (V)
Current(A)
Resist (Mohm)
Surge Status
Peak Volt(V) L1
Peak Volt(V) L2
Peak Volt(V) L3
Max P-P EAR%
EAR 1-2,2-3,3-1

Incoming
PASS
500
1.0
DA Only
PASS
2000
12.00
167 At 40C 66
PASS
2000
2000
2000
3.2%,3.3%,3.1%
No Test

DA/PI
Test Date/Time
DA Ratio
PI Status
Time (Min)
0:15
0:30
0:45
1:00
1:30
2:00
2:30
3:00

Motor ID O275467
6/29/2010 12:13:14 PM Voltage (V)
1.0
PI Ratio
PASS
Current(A)
2.59
2.59
2.50
2.50
2.50
2.50
2.50
2.50

Megohms
193
193
200
200
200
200
200
200

500
DA Only

Surge: Nested Waveforms

Test Date/Time
6/29/2010 12:13:14 PM
Lead
1
2
3

Peak Voltage (V)

2000
2000
2000

Motor ID O275467
Surge Status
PP EAR Status
PASS
PASS
PASS

PASS
Max P-P EAR%
3.2%
3.3%
3.1%

Pulse-to-Pulse EAR
Test Date/Time
Lead
1
2
3

6/29/2010 12:13:14 PM
Peak Voltage (V)
2000
2000
2000

Motor ID O275467
Surge Status
PP EAR Status
PASS
PASS
PASS

PASS
Max P-P EAR%
3.2%
3.3%
3.1%

Surge Phase-to-Phase Comparison

Test Date/Time
6/29/2010 12:13:14 PM
Compare
1-2
2-3
3-1

Peak Voltage (V)

2000
2000
2000

Motor ID O275467
Surge Status
LL EAR Status
No Test
No Test
No Test

PASS
L-L EAR%
15%
11%
24%