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Electric Motor Predictive Maintenance (PdM)

Deenergized (MCA™) / Offline
Energized (ESA) / Online
Assemblies (MCA™ + ESA)
AT7™ Pro
AT7™

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AT7™ Pro

Deenergized Motor Circuit Analysis™ (MCA) Diagnostic Instrument

The AT7™ Pro allows technicians to efficiently and accurately evaluate motors in the field, capture diagnostic motor data for condition monitoring, generate analysis reports, and more, on any type of motor — anytime, anywhere.

Test any motor’s resistance, stator, rotor, contamination and insulation stats all on one device and receive accurate diagnostics within as little as a few minutes.

In addition to the core functionalities of the AT7™, the AT7™ PROFESSIONAL has additional functionalities that test DC motor types, traction motors and transformers, and utilizes route based testing for data trending and analysis.

Use the AT7™ PROFESSIONAL for:

  • Offline testing of AC and DC motors, transformers, and generators
  • Testing installation and startup of new motors
  • Condition monitoring
  • Troubleshooting

The AT7™ Pro identifies:

  • Stator Issues
  • Rotor Issues
  • Ground Faults
  • Winding Faults
  • Open Connection Issues
  • Contamination Issues

Condition Monitoring

Using proprietary TVS Technology, the AT7 Pro allows users to conduct one simple, 3 minute test to create an overall ‘machine health’ condition to be trended over time. Deviations and/or fluctuations in the machine health value indicates a motor problem to be troubleshooted further.

Data can be transferred to a PC with MCA Software, for trending purposes, analysis, and generating reports.

Beyond Traditional Induction Motor Testing

Use the ALL-TEST PRO 7™ Professional’s patented Stator and Rotor Signatures™ to test rotors and stators with a single assessment. Additionally, use the AT7 Pro  to diagnose common fault types, for condition monitoring, and nuanced troubleshooting.

Initiated from the motor drive or motor starter, Motor Circuit Analysis™ evaluates the health of a motor in a non-destructive manner. Diagnose ground faults and test stator windings, cables, and induction motor abnormalities and receive results all on screen within minutes.

With the high-tech capabilities of the ALL-TEST PRO 7™, you and your technicians can easily detect even the most subtle imbalances in any motor.

Training

ALL-TEST Pro provides on-site and virtual comprehensive learning experiences that incorporate theory, new technologies, and practical field applications to educate attendees in the scope of motor diagnostics and comprehensive testing, including Motor Circuit Analysis™ (MCA™) and Electrical Signature Analysis (ESA).

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AT7™

Deenergized Motor Circuit Analysis™ (MCA) Diagnostic Instrument

The AT7™ allows technicians to efficiently and accurately evaluate motors in the field, capture diagnostic motor data to use for condition monitoring, generate analysis reports, and more — all on a hand-held device.

Features

  • Hand-held & Lightweight (under 1lb)
  • On-screen, step-by-step testing instructions
  • Quick Testing (less than 3 minutes per test
  • Test AC motors, generators & transformers
  • Condition Monitoring & Trending Capabilities
  • Advanced Troubleshooting Functions (Z/θ Test)
  • Upgradeable to the AT7 Professional
  • Remote firmware updates

USES FOR THE AT7™

Troubleshooting electric motors has never been easier. Test every AC motor type and evaluate the electrical health of motors by assessing their stator wings, rotors, cables and other components.

The AT7™ uses our patented Stator and Rotor Signatures™ to test squirrel-cage rotors and stators with a single assessment. Diagnose common fault type with Test Value Static™ (TVS™), which provides a sum calculated from a 3-phase MCA static assessment.

Easily detect even the most subtle imbalances in any motor — long before your motors fail as a result of preventable issues.

Electric Motor Troubleshooting 

Done Right

Troubleshoot any motor’s resistance, stator, rotor, contamination and insulation stats all on one device and receive accurate diagnostics within as little as a few minutes.

The AT7™ electric motor testing device is used detect motor abnormalities in electric motors across every industry.

Our handheld motor testing devices outperform our competitors’ products in both quality and usability.

While similar condition monitoring and motor troubleshooting tools are only able to detect ground faults, the AT7™ has the ability to detect motor failures before they occur and is a critical component of maintaining a facility’s productivity and overall ROI.

Use the AT7™ for:

  • Single Phase AC Induction (<1kV) manual test
  • Single Phase AC Induction (<1kV) auto-test
  • 3 Phase AC Induction-Squirrel cage rotor (<1kV) manual test
  • 3 Phase AC Induction-Squirrel cage rotor (<1kV) auto-test
  • AC Induction-Squirrel cage rotor (>1kV)
  • AC Induction wound rotor (<1kV) manual test **
  • AC Induction wound rotor (<1kV) auto-test
  • AC Induction wound rotor (>1kV)
  • AC Synchronous (<1kV) manual test **
  • AC Synchronous (<1kV) auto-test
  • AC Synchronous (>1kV)
  • Generators

Training

ALL-TEST Pro provides on-site and virtual comprehensive learning experiences that incorporate theory, new technologies, and practical field applications to educate attendees in the scope of motor diagnostics and comprehensive testing, including Motor Circuit Analysis™ (MCA™) and Electrical Signature Analysis (ESA).

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ATPOL III™

Energized Electrical Signature Analysis (ESA) Diagnostic System

The ATPOL III power quality analyzer and electric motor analyzer comprehensively evaluates the electrical and mechanical efficiencies of AC/DC motors, generators, and transformers.

The ATPOL III is the most advanced portable motor and power quality analyzer on the market.

It provides a comprehensive assessment of motor system health, from incoming power to the driven process.

When used with the ATPOL 8.0 ESA software, the system generates a detailed report on the entire motor system. This report includes:

  • Analysis of power quality
  • Motor performance
  • Mechanical components

It offers a clear view of efficiency and condition.

Testing Capabilities

  • The ATPOL III offers a comprehensive range of testing features designed to evaluate the full condition and performance of motor systems and their power supply. These capabilities include:
    • Complete electrical and mechanical motor analysis (ESA), including stator, rotor, and incoming power evaluation
    • Driven load diagnostics, detecting issues such as misalignment, unbalance, bearing wear, and mechanical looseness
    • Process performance analysis, identifying problems like cavitation or flow restrictions
    • Motor startup analysis, with transient waveform capture for identifying issues during acceleration
    • Full power quality surveys, assessing overall system health
    • Energy data logging, including real, apparent, and reactive power measurements
    • Harmonic analysis, identifying distortion that can affect equipment performance
    • Voltage and current monitoring, including balance, mismatch, and crest factor evaluations
    • 8-channel waveform display and capture, providing a detailed view of system behavior
    • Power disturbance detection, including voltage sags, swells, transients, and event capture
    • Incoming power assessment, to identify faults from the utility or supply side
    • Variable Frequency Drive (VFD) and DC controller circuit analysis, for advanced motor control systems

Use the ATPOL III for:

  • Measure critical electrical and mechanical variables, including line frequency, running speed, pole pass frequency analysis, gear mesh frequencies, hunting tooth frequencies, bearing defect frequencies for rolling element bearings, and blade or vane passing frequencies for fans or pump impellers.
  • Perform automatic analysis using priority algorithms and pattern recognition to detect common electrical and mechanical faults.
  • Automatically identify faults such as static or dynamic eccentricity and stator mechanical or electrical issues.
  • Evaluate incoming power quality, including harmonics, unbalance, and mismatch.
  • Automatically calculate voltage and current derating factors for more accurate system performance assessments.
  • Calculate efficiency for both AC induction and DC motors.
  • Conduct power analysis, including detecting sags, swells, and transients, plus energy consumption data logging.

Complete Motor Health Assessment

Electrical Signature Analysis (ESA) is a key tool in reliability improvement programs, especially in world-class maintenance strategies, due to its ability to detect faults in rotating equipment caused by forces. ESA is often more effective than machinery vibration analysis (MVA) because it doesn’t rely on measuring cyclic motion. In traditional vibration analysis, the amount of motion detected depends on Newton’s second law (F = mA), meaning that larger machines, which are more massive, require more force to produce detectable motion. In contrast, ESA uses the motor’s current as a sensor, directly measuring the force generated by developing faults. This allows ESA to identify problems much earlier than MVA, even before they produce noticeable vibrations. Furthermore, ESA is not limited by the types of sensors or the frequency constraints often associated with vibration analysis. It can detect faults across a broader range of conditions, making it a more versatile and early diagnostic tool for rotating equipment.

  • Induction windings
  • Rotors,
  • DC field windings
  • Armatures
  • Field and rotor coils in synchronous motors
  • Primary and secondary windings in transformers
  • Related connections and cables to ensure a complete analysis of the system’s electrical condition

Track, trend, and report with ESA SOFTWARE

Track, trend, and report on the condition of your plant’s motor assets with ease using the ALL-TEST PRO On-Line III™ ESA Software (for PC). This powerful software helps you efficiently manage and monitor the health of your motors.

The software uses proprietary algorithms and spectral patterns to detect and evaluate abnormal conditions in the motor system, providing clear, easy-to-understand fault detection and reporting. When paired with the ALL-TEST PRO On-Line III™, the software analyzes both the electrical and mechanical condition of the entire motor or generator system.

The ESA software offers superior diagnostics for AC motors, evaluating key components like the stator (both electrically and mechanically), rotor, air gap, and the full driven load (whether belted, geared, or bladed). Additionally, it provides excellent diagnostics for DC motors, generators, and transformers.

In addition, ESA software provides excellent diagnostics for DC motors, generators and transformers.

Features

  • Lightweight & Portable: Compact handheld design, weighing approximately 1 lb—ideal for use in the field or on the shop floor
  • Fast Testing: Complete tests in as little as 10 seconds; high-resolution motor diagnostics available in 60 seconds
  • Long-Distance Testing: Virtually unlimited distance between the motor and load, making it ideal for hard-to-reach or submersible equipment
  • Early Fault Detection: Identifies developing electrical and mechanical faults at their earliest stages—before failure occurs
  • Superior Mechanical Diagnostics: Detects many mechanical faults earlier than traditional methods, such as vibration or infrared analysis
  • Access to Hidden Faults: Measures conditions and faults not accessible by other diagnostic techniques
  • Enhanced Safety: Bluetooth® wireless communication allows technicians to operate the device and collect data remotely, reducing exposure to energized equipment
  • Efficient Asset Management: Built-in Test Plan Manager supports route-based testing and trend analysis for streamlined condition monitoring across multiple assets

Comprehensive Motor and Power Quality Analysis

The ATPOL III™ is the most advanced energized motor and power quality analyzer available. It offers comprehensive electrical signature and power analysis for AC and DC motors, generators, and transformers.

The ATPOL III™ Electrical Signature Analysis (ESA) tool allows you to perform detailed diagnostics on your motor systems. The tool provides a complete evaluation of electrical and mechanical health, including:

  • Rotor and stator conditions
  • Air gap integrity
  • The entire driven load, whether geared, bladed, or belted.

When paired with ESA™ software for PC, the ATPOL III™ provides clear insights into operational electrical and mechanical performance.

Safe Testing

The ALL-SAFE™ accessory for the ATPOL III™ provides major advantages over traditional methods for collecting data during energized testing while the motor is operating. Its quick-connect feature allows testing without the need to open electrical panels, eliminating the need for bulky protective gear. The ATPOL III™ with ALL-SAFE™ ensures safety, ease of use, accuracy, and superior diagnostic results, making it the ideal accessory for ESA motor testing.

The Highest Standards

The ATPOL III™ has passed the highest standards for CAT III 1000V. The CAT IV 600V rating signifies it is suitable for testing at the service entrance (≤ 600V).

Obtain Optimal ROI

Identifying motor faults before they cause a breakdown can save your organization valuable time and significantly reduce costs. The ATPOL III™ combines two powerful tools in one device: a complete Power Quality Analyzer (PQA) and a full-featured Electrical Signature Analyzer (ESA).

In PQA mode, the ATPOL III™ provides:

  • Energy data logging
  • Harmonic analysis
  • Voltage and current charting
  • Waveform viewing
  • Capture of sags, swells, transients, and other power events
  • Startup transient current capture

In ESA mode, it evaluates:

  • Incoming power quality
  • Motor control circuit health
  • Motor condition
  • Driven load performance

Stay Safe with the ALL-SAFE PRO®

Collecting energized testing data while a motor is under load requires an innovative solution to maintain operator safety.

The ALL-SAFE PRO® is a permanently installed connection accessory for the ATPOL III™ energized testing instrument. With this electric motor connection box, the ATPOL III™ can quickly and easily perform tests while the motor is energized and under load without the operator having to open the electrical panel and wear bulky personal protective equipment (PPE).

The ALL-SAFE PRO® features split-core current transformers (CT) for both the 100A and 1000A versions, making it unnecessary to disconnect motor phase leads when installing the current transformers. This saves valuable time and reduces costs during installation.

Split-core current transformers (CT) for the 100A and 1000A versions of the ALL-SAFE PRO® make it unnecessary to disconnect motor phase leads when installing the current transformers – saving substantial time and money.

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MD III™

Energized (ESA) + Deenergized (MCA™) Testing Instrument Package

Motor Circuit Analysis™ (MCA™), Electrical Signature Analysis (ESA), and a Power Quality Analyzer in just one package to evaluate and trend the health of your entire motor system.

 

MD III™ Includes

  • 1 ALL-TEST PRO 7™ PROFESSIONAL (Includes device, software, leads & strap wrench)
  • 1 ALL-TEST PRO ON-LINE III™ (Includes device, software & leads)
  • 1 rugged, hard carrying case
  • 2 AC chargers (115/230V)
  • Instruction manuals
  • One year warranty

Training

ALL-TEST Pro provides on-site and virtual comprehensive learning experiences that incorporate theory, new technologies, and practical field applications to educate attendees in the scope of motor diagnostics and comprehensive testing, including Motor Circuit Analysis™ (MCA™) and Electrical Signature Analysis (ESA).

 
 

Features

  • Fully Comprehensive – includes both MCA™ and ESA equipment for online and offline testing
  • Track, Trend & Report – Software for condition monitoring
  • Handheld & Lightweight – Approx. 1lb per device
  • Fast – 60 second tests
  • Testing distance – ESA virtually unlimited between motor and load (including submersible equipment)
  • Early alert – detects faults at early stages before motor and motor system failure

ADVANTAGES OF THE ALL-TEST PRO MD III™

The ALL-TEST PRO MD III™ motor testing assembly is used to monitor the health of any motor type, testing power quality, connections, harmonic distortion, alignment, insulation, rotors, bearings, air gaps, stators and more.

The included predictive maintenance tools feature two cutting-edge motor testing instruments (AT7 Pro and ATPOL III), a sturdy carrying case, AC chargers, and step-by-step instructions for optimal functionality.

The ALL-TEST PRO MD III™ motor testing assembly provides automatic diagnostic reports that measure all aspects of a motor’s performance, and it’s backed by an extendable one-year warranty.

The ALL-TEST PRO MD III™ reports provide indications of:

  • Early winding faults
  • Rotor problems
  • Incoming power issues
  • Electrical and mechanical motor condition
  • Driven load mechanical condition

The ALL-TEST PRO MD III™ motor testing assembly eliminate problems with your machinery before they cost you thousands in lost work time and repairs.

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