Synchronous Machine Testing With ALL-TEST Pro Instrumentation

Dr. Howard W. Penrose, Ph.D.

Introduction

In order to further understand the application of motor circuit testing and analysis on
synchronous electric motors (synchronous machines), it is important to have a brief
overview of the operation of a synchronous motor, most common faults, common test
methods, how the ALL-TEST IV PRO™ works with large synchronous motors, basic steps
for analysis of synchronous stators and rotors, and, expected test results (Editor- ALL-
TEST PRO 5 is the recommended replacement for the ATIV). In this paper, we will
discuss these various aspects, referencing other materials for additional details.

About Synchronous Machines

Large synchronous motors have two basic functions:

 The first is to improve the electrical power factor in a plant. In any plant with large
inductive loads, such as motors and transformers, current begins to lag behind
voltage (poor power factor). When this becomes severe enough, the plant requires
significantly larger amounts of current to perform the same amount of work. This
can cause voltage sag and overheating of electrical components. A synchronous
motor can be used in such a way as to cause little to no impact on power factor,
or can be used to cause current to lead voltage to correct power factor problems.
 The second method of operation is to absorb pulsating loads, such as reciprocating
compressors. Once a synchronous motor has achieved synchronous speed, it has
coils which ‘lock’ in step with the electric motor’s rotating magnetic fields from the
stator. If a torque pulse occurs (such as at the top of a reciprocating compressor
stroke), the motor may come out of synch with the rotating fields. When this
occurs, a special winding on the rotor called an amortisseur winding (see
synchronous construction below) absorbs the energy from the torque pulse,
keeping the rotor in synch.

The basic construction of a synchronous motor is straightforward. There are three sets
of windings, a stator, a rotor, bearings, and either a generator (brushless) or a ‘static
exciter’ (brush-type). The windings consist of: A standard three phase winding, very
similar to a standard induction electric motor; A set of field coils, which are DC coils made
of round wire for small machines and rectangular or ribbon wire on larger machines; And
an amortisseur winding, which is similar to an induction motor rotor squirrel cage.

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The starting methods for both the brush-type and brushless synchronous motors are
similar. The starting circuit will be different for both. Following is a description of the basic
mode of operation, followed by a brief description of the differences:

During the starting phase of a synchronous motor, it acts much the same as a standard
induction motor. The stator receives an electrical current and a rotating magnetic field is
developed (the speed = (120 * applied frequency) / # of poles). This field generates a
current in the amortisseur winding, which is used to develop starting torque by generating
its own magnetic field which interacts with the stator magnetic field in the air gap and
causes the rotor to follow the stator magnetic fields. As the rotor starts to catch up to the
stator fields, DC current is injected into the rotor field coils, creating north and south
magnetic pairs (rotor coils are always found in pairs). These lock in step with the stator
magnetic fields and follow at the same speed as the stator fields, whereas a standard
induction motor always lags behind.
In a brush machine, the DC source for the rotor fields usually comes from a ‘static’
(electronic) starter, which converts a supplied AC power to DC. In most cases, the output
DC is varied through the starting cycle. The drive may also be set up to short out the field
coils of the machine to avoid rotor saturation and the resulting extremely high currents on
the stator. Once the rotor begins to turn, DC is supplied to assist the motor in developing
torque. The DC voltage is supplied through a pair of slip rings and brushes.

In a brushless machine, a DC generator is installed directly on the shaft of the

synchronous motor. As the synchronous motor starts, the generator provides very little
DC through its commutator. As the speed increases, the DC voltage also increases,
helping the motor generate torque then lock in step at synchronous speed. In this type
of machine, the generator is wired directly to the rotor fields.

There are also machines that have a generator mounted on the shaft of the rotor that
feeds a separate control. This is used to first short the windings and then control the
amount of DC fed to the rotor, just as the brush machine.

Most Common Synchronous Motor Faults

Large synchronous motors tend to be well built and sturdy. They are often overbuilt with
material to withstand the severe loads that are applied. The most common failures for
industrial synchronous machines, in order, are:

 Bearings due to general wear and contamination

 Rotor fields – due to high temperatures, these will often burn up from the inside
out
 Amortisseur windings – mostly in reciprocating loads. Because of the amount of
energy absorbed, the winding bars will often crack. In particular if the rotor fields
are beginning to fail and short, making it easier for the rotor to fall out of ‘synch.’
 Stator windings – general wear and contamination. Stator windings in
synchronous machines tend to be ‘form wound’ and heavily insulated.

©2015, ALL-TEST Pro, LLC Rev. 07/10/2015

Almost all of the winding faults that occur in a synchronous motor start between
conductors in the rotor or stator coils.

Common Test Methods, Strengths and Weaknesses

Following are the traditional test methods for evaluating the condition of a synchronous
motor:

 Insulation resistance testing: Using applied DC voltages as specified by IEEE 43-

2000, a potential is placed between the stator windings and ground. This
measures only direct faults between the stator windings and the stator frame. Is
also performed through the slip rings on a brush type machine.
 Polarization Index: Is a 10 minute to 1-minute ratio of insulation resistance. This
has been traditionally used as a method to gage the condition of the insulation
between the stator windings and frame. As with insulation resistance testing, this
can also be performed through the slip rings on a brush type machine. As stated
in IEEE 43-2000, this test method is only truly valid on pre-1970 insulation
systems.
 High Potential testing: Most common on large machines is DC high potential
testing which is performed at a value of twice the motor nameplate voltage plus
1000 volts, times the square root of 3. On an existing insulation system, this value
is often reduced to 75% of the potential voltage. This test highly stresses the
insulation system and is potentially damaging (per IEEE Std’s 388 and 389). This
type of test should NEVER be applied to the rotor windings of a synchronous
motor.
 Surge Comparison testing: Evaluates the turn-to-turn condition of the stator only
by comparing the waveforms of two windings when a fast rise time pulse of twice
the voltage plus 1000 volts. If there are correctable issues, such as contaminated
windings, this test may damage the motor windings.
 Partial Discharge testing: Is a non-destructive test method that measures radio
frequencies from discharges in voids within the insulation system of the motor
windings. This is effective for trending on machines that are over 6.6 kV and only
provide a brief warning from 4 kV. It does not detect any rotor faults.
 Motor Current Signature Analysis: Was designed for rotor testing of induction
motors.
 Voltage Drop Test: Requires that the motor is disassembled. A 115 AC voltage is
applied to the rotor windings and the voltage drop is measured with a voltmeter
across each coil. If there is a short, the voltage drop will vary more than 3%.
The above list does not include equipment for mechanical testing of synchronous motors.

About the ALL-TEST Pro Instrument

The ALL-TEST IV PRO™ (Editor- ALL-TEST PRO 5 is the recommended replacement

for the ATIV) is a simple electronic instrument that performs in much the same manner

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as a multi-meter, except that it provides a series of readings that cover the AC parameters
of the motor circuit. It is a data collector and tester that sends a low voltage DC signal for
simple resistance testing, in the same manner as a milli-Ohm meter, and a low voltage,
high frequency AC signal for AC readings. The instrument then measures and calculates
test results in engineering units of resistance, impedance, inductance, phase angle,
current/frequency response and an insulation resistance test to ground.

The primary differences between electronic testing of power equipment versus traditional
power methods are:

 A more complete view of the motor circuit, including influences from changes in
the condition of rotor field coil insulation.
 One instrument for a large range of equipment size. The test is limited only to the
simple resistance range of the instrument (0.010 Ohm to 999 Ohms).
 Non-destructive – no harmful voltage is applied.
 Easier data interpretation – A few simple rules for data interpretation (See data
interpretation below).
 Hand held vs. equipment that may weigh from 40 lbs to well over 100 lbs.
 Internal power source for the instrument.

As an insulation system ages, or if the insulation system is contaminated and it is effecting

the integrity of the insulation, the electrical circuit of the motor changes. Because the
rotor is an integral part of the circuit, changes to the electrical integrity of the rotor circuit
and insulation system are directly reflected through the stator windings, as well. This
allows both immediate troubleshooting and long-term trending of the motor.

Unique test information allows the ALL-TEST Pro Instruments to view enough parameters
of the insulation system to detect and isolate:
 Shorted stator windings
 Shorted rotor fields
 Broken amortisseur winding bars
 Air gap eccentricity
 Winding contamination (rotor and stator)
 Ground insulation faults

Basic Steps for the Analysis of Synchronous Machines with ALL-

TEST Pro Instruments

The steps for testing synchronous machines are similar to those for evaluating the
condition of standard induction motors. However, because there are field coils on the
motor rotor, a few additional steps are involved when troubleshooting a fault.

When testing a synchronous machine from the motor control center or starter:

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  De-energize the equipment. Ensure that secondary sources of power are also de-
energized.
 Perform the standard ALL-TEST IV PRO™ (now AT5) tests on the stator following
the menu prompts on the instrument.
 Evaluate the test results (See Expected Test Results)
 If a fault is indicated, begin troubleshooting:
o Adjust the position of the rotor, as much as possible, up to 45 degrees (any
movement will do if the rotor is difficult to turn, but no less than 5 degrees)
o Re-perform the tests and review the readings. If the fault has shifted, or
changed by more than a digit, then the fault most likely is located in the
rotor.
o If the fault remains stationary (does not change with rotor position), then
disconnect the leads at the motor terminal box and retest. If a fault is still
indicated, it is most likely in the stator, if not, it is most likely in the cable.

The average test time, other than troubleshooting, is approximately 3-5 minutes.

When testing a disassembled synchronous machine, it is important to remember that the

readings will be very different without the rotor in place:

 Perform the ALL-TEST IV PRO™ Auto test (AT5 Z/ test mode) on the stator and
evaluate the test results. This will provide an immediate indication of any faults.
 For the rotor test:
o Perform the Auto test and compare to a past reading; or,
o Perform the Auto test and compare to an ‘identical’ rotor; or,
o Perform the Auto test across each field coil instead of a voltage drop test.
o All parameters for all three should meet the evaluation limits.

Because of the style of testing, these results can be trended and compared between like
machines.

Other applications for motor circuit testing include evaluation and acceptance, and predictive
maintenance.

Expected Test Results

As mentioned in the last section of this paper, the test results are similar to those found in
three phase induction machines. Fault patterns are very straightforward and apply regardless
of equipment size, within the test range of the ALL-TEST Pro Instruments. Following is a brief
overview of the test measurements and their results for basic troubleshooting:

 Simple resistance measurements: Are an indicator of high resistance connections,

loose connections or broken conductors in the circuit. This test is important, especially
if the resistance problem is in one spot as, based upon I2R, a resistive spot will put out
a great deal of heat energy (in Watts). For instance, a 0.5 Ohm resistance across a
point in a circuit that is seeing 100 Amps would give off: (100Amps2)(0.5 Ohms) =

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 5,000 Watts (5kW) worth of energy. This is about the same energy used to turn 6
horsepower worth of electric motor.
 Inductance measurement: Is an indicator of magnetic strength of a coil and the
influence of other coils on one coil. It is impacted by the number of turns in a circuit,
the dimensions of the coils and the inductance of other coils. This measurement, by
itself, is only a good indicator of the condition of the amortisseur winding and rotor
eccentricity. Inductance will only show a shorted winding if it is severe.
 Impedance measurement: Is the measurement of the complex resistance in the circuit.
It can be used, much like inductance, for checking the amortisseur winding and rotor
condition. However, when used along with inductance, it can be used to detect
overheated windings and winding contamination quickly. By viewing the relationship
of inductance and impedance between each phase: If the inductance and impedance
are relatively parallel, then any inductive and impedance unbalance is in the
relationship between the rotor and stator (rotor position); If they are not parallel, this is
an indication of an insulation problem such as insulation breakdown or winding
contamination.
 Phase angle and I/F (Current/Frequency): Are both indicators of insulation faults
between turns in the stator or rotor.
 Insulation Resistance: Evaluates the insulation to ground and will only indicate when
the insulation has failed.

The test limit recommendations, as outlined in the “Guideline for Electronic Static Winding
Circuit Analysis of Rotating Machinery and Transformers,” are as follow:

Table 1: Test Limits (peak-to-peak values)

Measurement Limits

Resistance 5%

Impedance ~ 5%*

Inductance ~5%*

Phase Angle +/- 1

I/F +/- 2

Insulation Resistance > 100 M-Ohms

*Can exceed this value if measurements are parallel.

Following is an overview of the troubleshooting rules:

©2015, ALL-TEST Pro, LLC Rev. 07/10/2015

  Shorted Windings:
o Shorted windings can be evaluated by viewing the phase angle and I/F
readings from the instrument on similar coils or between phases:
o Phase Angle (Fi) – The phase angle should be within 1 digit of the average
reading. For instance, a reading of 77/75/76 would be good because the
average reading is 76. A reading of 74/77/77 would be bad.
o Current Frequency Response (I/F) – The current frequency response should
be within 2 digits of the average reading. For instance, a reading of –44/-45/-
46 would be good. A reading of -40/-44/-44 would be bad. However, a reading
such as -42/-44/-44 should be considered suspect.
 Winding Contamination and Rotor Position
o The position of the rotor within the electric motor may cause a natural phase
unbalance. Winding contamination will also cause phase unbalances. Evauate
the DF %..
o Rotor Position – Rotor position unbalances can be evaluated by looking to see
if the inductance and impedance values are fairly balanced. For instance, if
there are inductances of 17/18/19 and impedances of values 24/26/29, then the
unbalance is due to rotor position. This may also be the case if the inductances
are 5/5/5 and the impedances are 8/9/8.
o Winding Contamination – Can also be found as overheated (burned) windings.
These conditions are the result of changes to the insulation due to breakdown
of the insulation system.

Conclusion
Through a set of simple rules and instructions, the ALL-TEST IV PRO™ (now AT5) provides
an excellent tool for troubleshooting and trending the condition of synchronous machines. The
test is performed using simple, non-destructive test measurements that allow for a more
complete view of the motor stator and rotor circuit than any other test. Test evaluation is
simple and direct, regardless of equipment size or type.

Bibliography

 Guideline for Electronic Static Winding Circuit Analysis of Rotating Machinery and
Transformers, BJM Corp, ALL-TEST Division, 2001.
 Penrose, Howard W. Motor Circuit Analysis: Theory, Application and Energy Analysis,
SUCCESS by DESIGN, 2001.

©2015, ALL-TEST Pro, LLC Rev. 07/10/2015