3 Day Motor Circuit Analysis Seminar Using the AT5™

Course Type: On-Site Classroom
Course Number: 10044

Three days, at the customers’ site, of ESA (Energized) training. This course picks up where the ESA Level I course leaves off. It begins with a brief review of the basic FFT theory, with the addition of more advanced FFT theories as it progresses. The course continues to use a hands-on approach to introduce the use of shaping & aliasing filters in the FFT to gain a better understanding of the presented signal for more accurate analysis. It also covers many of the advanced features of the ATPOL II™ software such as advanced data base setup, SD card operation for routes and trending.

An introduction to the power quality issues that can result in high energy usage, costs or high maintenance costs. PQ issues can lead to equipment instability or eventual failure. It discusses some of the adverse effects that PQ has on electrical equipment operation. Discussions will include power quality issues such as harmonics, voltage unbalance, dips & swells and transients. It also presents the use of additional electrical displays such as time waves & polar graphs for better understanding of any issues or anomalies of the incoming current and voltage signals.

Electrical Machine construction and operating principles are discussed focusing on the construction, assembly & operating principles. This includes AC 1 & 3 phase induction & synchronous motors, 1 & 3 phase transformers, DC motors & generators, wound rotor motors & asynchronous generators. This review focuses on the operating principles and manufacturing or assembly errors that create the dynamic forces, which result in higher operating or maintenance cost. These principles help the attendees understand the source or cause of these faults, how they occur in the motor system & what can be done to correct them.

Further discussion is presented involving the failures of the bearings that separate the rotating and stationary components, the common failure modes, & how to identify them using ESA. It will discuss faults and malfunctions associated with all types of rolling element as well as fluid film type or plain bearings.

The course continues with discussions about additional electrical and mechanical faults that are encountered by electrical machines as well as mechanical faults that occur within mechanical machines driven by electric motors. This includes gear boxes, fans, generators, wind turbines, horizontal & vertical pumps, or any other machine driven by any electrical machine. A brief discussion of hydraulic issues that occur in fluid systems, such as cavitation, recirculation and flow related resonance will be presented.

The course finishes with a discussion on testing and identifying faults on motors driven by specific electrical controllers such as VFD’s & DC Controllers. And an introduction to the use of advanced ESA s/w features such as waterfall displays, torque ripple, and spectral comparison and trending. This course prepares you to evaluate all types of electrical machinery systems and look for electrical and mechanical existing or developing problems, anywhere in the motor system.

Course uses the ALL-TEST Pro instruments, but the theories and principles presented are applicable for all Energized motor testing systems. Course materials Required: Attendee Workbook, ESA 5.0 Software, & ESA Exercise Disk, provided by ALL-TEST Pro, LLC. Laptop with administrative access (must run Windows XP or later) provided by the student. 

Course Objectives

Upon successful completion of this course students should be able to:

  • Take data using the ATPOL II™ analyzer both locally and remotely on electrical equipment
  • Transfer data captured from an SD card to a host computer route-based machine hierarchy
  • Use the advanced features of the ESA software such as waterfall displays, torque signatures, and comparative analysis
  • Define Power Quality and discuss the impact of PQ issues towards electrical efficiency, electrical reliability, and energy costs 
  • List the different types of electrical equipment, identify their components and describe the purpose of each component
  • Explain the operation of the different types of electric equipment
  • Describe the stages of rolling element bearing failure and explain how ESA identifies the condition of these types of bearings
  • What is meant by pole pass frequency (PPF) & how is it calculated
  • Determine Motor Shaft Speed based on Measured Values of Voltage, Current, Nameplate Speed and Rated Power and calculated PPF
  • Describe the electrical & mechanical faults can be analyzed with ESA and what causes these faults & guidelines on how to correct them
  • Discuss the relationship of Dynamic Load and bearing life
  • Discuss the effects of Resonance in a mechanical system and what it will do to the electrical spectrum
  • Discuss guidelines on how to confirm and correct mechanical resonance issues
  • Explain what gear faults or issues create dynamic forces between gears during operation under fault conditions
  • Discuss how to determine which gear is at fault when gear problems are diagnosed using ESA
  • Understand and define the terms used in ESA
  • Evaluate the condition of a squirrel cage rotor using the ESA spectrum and determine severity of the fault and most likely causes
  • Explain the faults that causes Static Eccentricity
  • Define a thermally sensitive rotor and explain how it affects the Electrical Signature
  • Identify which displays, Hi Frequency, Lo Frequency or Demod spectrum faults will be used to identify all the electrical & mechanical faults
  • Understand how to set up ATPOL II™ for various electrical testing, such as transients & PQ studies
  • Reprogram the ATPOL II™ using an SD card
  • Discuss the types of DC motor controller faults that will be identified from the electrical spectrum
  • Discuss the types of VFD faults that can be identified using the energized motor data captured by the ATPOL II™
  • Demonstrate the ability to set up and perform predictive maintenance routes and upload the test data using the ATPOL II™
  • Set-up and implement an energized motor testing program using the ATPOL II™

Additional Course Information

Technology or Other Requirements: Students attending this course must bring their own laptop. Laptop must have administrative rights to install software. Minimum operating system and software to be installed on the laptop should be Windows XP, with Microsoft Word and Excel 2003.

Format: Blended, Self Paced and Instructor Lead Classroom

Assessment Style: Graded Test, Pass/Fail

Cost: $ 10,645.00 USD, Price includes course material for up to 10 attendees, instructor’s travel & expenses in the USA & Canada. Prices may vary for events held outside the United States and Canada.

Duration: : 3 Days/22 Instructor Led Hours,2 Self paced hours

CEU Award: ALL-TEST Pro, LLC is authorized by IACET to offer 2.4 CEUs for this program. As an IACET Accredited Provider, ALL-TEST Pro, LLC offers CEUs for its programs that qualify under the ANSI/IACET Standard.

Instructor: William Kruger