PdMA MCEGold PRODUCT SUPPORT MANUAL HARDWARE

CHAPTER 2: HARDWARE
A tester has three major hardware components: Shipping Case, Tester, and Accessory Bag.

Tables at the end of this chapter list specifications for the shipping case, tester case, and
MCE and EMAX version of the tester.

SHIPPING CASE
The shipping case shown in Figure 2-1, designed for storage and shipping of the tester and
accessory bag, is made of Lexan and has aluminum runners. It has steel feet, handles, and
latches. The hinged cover has two latches to ensure positive closure. One of the latches
has a hasp to allow locking the case.

There are two side handles on the shipping case for ease of carrying. The shipping case is
approximately 22.5" long by 18.5" wide by 18" high. It weighs approximately 35 pounds
empty and 75 pounds with the tester and all accessories enclosed.

The interior of the shipping case has two compartments carved out of closed cell foam;
one for the tester and one for the accessory bag.

When returning the tester to PdMA for upgrades, annual calibration, or repair, it is
imperative that you ship the tester in the shipping case. Severe damage to the tester may
occur during shipping if it is not protected in the shipping case. Prior to sending the tester
to PdMA, follow the instructions at the end of Chapter One, in the section titled
Returning the Tester to PdMA.

Specifications for the shipping case are found in Table 2-3, on page 2-16.

Figure 2-1: Shipping Case

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TESTER
Case
The tester is enclosed in a waterproof, injection molded, black ABS plastic case. See
Figure 2-2. The plastic hinge and stainless steel latch pins will not dent or corrode. The
large ergonomically designed handle is cushioned. The case can withstand temperatures
from -15 to 160 F (-25 to 71 C).

For security purposes, the case is lockable, by placing a lock (not provided) in the area
provided beside the latch.

The case is 18.2x14.5x6 inches (46.99x36.83x15 cm). It weighs approximately 19 pounds

(8.62 kg) empty and 23 pounds (10.43 kg) with the laptop computer installed.
Specifications for the tester case are found in Table 2-4, on page 2-16.

Figure 2-2: Tester Case

The top cover of the case does not remove. Inside the cover are two clips designed to hold
the EMAX data acquisition cable. To avoid damage to the cable, it must be removed from
the laptop computer and placed in the clips provided before closing the cover or removing
the laptop computer.

The laptop computer rests on the tester deck as shown in Figure 2-3. The deck contains a
battery holder, battery indicator, fuses, and connections for the computer, current probes
cable, voltage probe, and MCE.

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Figure 2-3: Tester Case with Laptop Computer

Figure 2-4, shows an MCEGold tester. The various tester components are numbered and
described following the figure. MCE Specifications are found on page 2-14 and MCE
Electrical Specifications are found in Table 2-1 on page 2-14. EMAX Specifications are
found on page 2-15 and EMAX Electrical Specifications are found in Table 2-2 on page 2-
15.

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Figure 2-4: Tester Case Components

Components
1. Serial Number Tag A Serial Number Tag is assigned to every unit. PdMA
Corporation uses this number to identify the unit for repairs, updates, etc.

2. Identification Label This label provides information such as model number,

equipment-input rating, battery installation/removal instructions, warning/safety
advice, and PdMAs contact information.

3. Connection Identification Label This label identifies the location of each test lead
connection used with the system and provides reference for the remaining voltage/
time level of the battery.

4. Liner The liner supports the majority of components that are used when operating
the unit. It is designed with a wide flat area, to allow various types of laptop
computers to be utilized with the system.

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5. Computer A laptop computer is used to run the software interface that

communicates with the printed circuit boards located inside the unit.

6. Battery Compartment The battery compartment is the designated location for the
battery that supplies DC power to the unit. Refer to the Identification Label for the
recommended battery and its installation/removal instructions.

7. Communication Ports Connector Communication Ports is the connection between

the computer software and measuring hardware interface (printed circuit boards) of
the system. It consists of two ports, a RJ45 (eight conductors) type connector and a
RJ12 (six conductors) type connector. The RJ45 connects the laptop computer to the
internal MCE/EMAX printed circuit boards by the use of a RJ45 Cable (See #8). The
RJ12 permits the external AIS (Advanced Insulation System) unit to communicate
with the laptop computer software. The AIS is optional equipment.

8. RJ45 Cable This cable enables communication between the laptop computer
software and the internal printed circuit boards of the system. It consists of a cable
with a DB-9 type plug on one end and a RJ45 type plug on the other end. The DB-9
plug connects to the nine pin communication port connector located on the back of
the laptop computer. The RJ45 plug connects to the RJ45 port in the communications
port connector.

9. DAQ/216B Cable The DAQ/216B Cable enables the EMAX printed circuit board to
communicate with the laptop computer software. This cable connects to the PCMCIA
DAQ/216B card supplied with the unit. The cable is to be connected only when an
online test is to be performed. It must be disconnected and attached to the holding
clips prior to the removal of the laptop computer and/or closing the unit.

NOTE: Failure to disconnect the DAQ/216B Cable prior to the removal of the laptop
computer and/or closing the unit will result in the destruction of the cable and/or the
PCMCIA DAQ/216B card.

10. DAQ/216B Cable Holding Clips These clips are used to store and hold the DAQ/
216B Cable away from the risk of damage.

11. Fuse Holders Fuses are used for circuit protection during an online test. They are
labeled Phase 1, 2, and 3. The replacement fuse type is F/0.1A/500V/6x32mm.

12. Voltage Configuration Switch This switch is used to change the location of the
voltage measurement for an online test. The switch provides two configuration
options, Common and Phase 2. Common is used when testing normal four wire
grounded distribution systems. Phase 2 is used for open delta potential transformer
configurations.

13. Battery Level Indicator This indicates the remaining life of the battery (test time). A
fully charged battery will provide approximately 3.5 hours of test time and the green
area of the indicator will be lit. When the indicator reaches the yellow region, a test
life of approximately two hours is expected. It is recommended that when the
indicator reaches the red area any on-going test is finalized, close the software, turn
off the tester, and replace the battery with a fully charged battery.

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14. Current Probe Cable Connector This connector is used for capturing AC current
signals during an online test.

15. Voltage Probe Connector This connector is used for capturing AC voltage signals
during an online test.

16. MCE Test Lead Connector This connector is used for offline motor circuit analysis.

NOTE: DO NOT input AC or DC voltage through this connector. Follow the correct
procedure to ensure that there is no voltage present in the circuit to be analyzed.

17. Case The case is made of a high impact grade ABS plastic, designed to protect
against jarring, vibration, and crushing.

18. Silicone Seal A silicone O-ring is installed on the lid and seals out water, salt air,
and some gases, when the unit is closed.

19. Closing Latch There are two latches which are used to hold the lid in a closed
position when carrying or storing the unit.

20. Locking Port For security purposes, a lock (not provided) can be placed through the
hole in the locking port during travel or storage of the unit.

21. Handle The carrying handle is cushioned.

Tester Battery
For installation and removal of the tester battery, follow the instructions located on the
inside of the top cover of the tester case.

The supplied battery is a Panasonic HHR-V60, 6 Volt, 6.0 Amp-Hour, Nickel Metal
Hydride (Ni-MH). Do not use the battery below 32 F (0 C) or above 104 F (40 C). A
thermal protective safety device in the battery prevents operation or charging at
temperatures above 196 F (91 C).

The battery is shipped in a partially charged state and must be fully charged before use.
Refer to the instruction manual that came with the supplied charger for charging
instructions. When charging the battery for the first time or after a prolonged storage time,
it is normal for the charger to indicate that charging has been completed after 10 to 15
minutes. Remove the battery from the charger and repeat the charging procedure. It is not
necessary to fully discharge the battery between charges, nor is it necessary to periodically
recondition the battery. The battery charge may be topped off at anytime without adverse
affects to the battery.

A fully charged battery lasts approximately four hours under constant testing. Batteries
may last a full eight hours or longer, depending on the types of tests selected. The amount
of time remaining on the battery depends on the status of the charge at the beginning of
testing, the type of testing that is being performed, and the age and condition of the
battery.

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The battery charge level is indicated by an LED display, located on the tester deck below
the battery holder. As the battery discharges, the LED indication moves from top (fully
charged) to bottom (fully discharged). To the right of the LEDs is a green-yellow-red (top
to bottom respectively) battery status scale. Green indicating fully charged and red
indicating discharged.

PdMA recommends that you shut down the tester before the battery is completely
discharged, recharge the battery, and resume testing. Alternatively you may shut down the
tester before the battery is completely discharged, replace it with the spare, fully charged
battery and resume testing.

When the battery needs to be charged, remove it from the tester and place it in the supplied
charging unit. DO NOT REMOVE THE BATTERY FROM THE TESTER WHILE A
TEST IS IN PROGRESS. The battery is fully charged when the red light on the charger
extinguishes. The charger will automatically shut off when charging is complete.

If the battery is not significantly discharged and you will not be using it for the next two to
three days, it is recommended that you store the battery as is and recharge it before use. If
you will be storing it for longer than two weeks, it is recommended the battery be fully
charged before storage and after that every six months while it is in storage. Do not store
the battery in the tester battery compartment or the charger.

Battery life will be reduced by repeated operation or storage at extreme temperatures and
overcharging.

Laptop Computer

WARNING: This laptop computer has been specially configured to operate your new
MCEGold tester. Any changes made to the laptop settings including BIOS, config.sys,
Autoexec.bat, Power Management, Serial or Parallel Port, etc. may render the tester
inoperable.

Installing software which uses the serial or parallel port could also adversely affect the
operation of the tester.

P l e a s e c o n t a c t o u r Te c h n i c a l S u p p o r t a t ( 8 1 3 ) 6 2 1 - 6 4 6 3 e x t . 2 5 1 o r
techsupport@pdma.com if you have any questions.

General
The exact model of laptop computer your tester has depends on when your tester was
built. Refer to the computer manufacturers literature, supplied with the tester, for specific
information on operation and maintenance of the laptop computer, installation of software,
charging and maintenance of the battery, etc.

To install and operate/run MCEGold, you must have the following minimum requirements
(subject to change):

Windows XP SP2

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1.73 Ghz sxga + Intel/GMA900 for max screen resolution

80 GB hard disk drive 7200 RPM

1.0 G RAM (memory)

1 G available on the hard drive. Hard drive consideration should be given to the size
of the database being converted. After conversion, the database may be as much as
four times larger than the original database.

24x CD-RW + DVD reader

MCEGold software (installed on computer, backup software CD supplied)

Primary computer battery - 6 cell for higher amp/hour

Laptop Battery
Usually the laptop battery is a Panasonic #HHR-V60A/1B 6-volt, 6-amp-hour, nickel
metal hydride (Ni-MH) cell which lasts approximately 2-4 hours when fully charged. The
battery automatically charges when the computer is plugged into an AC power source. DO
NOT change batteries while the computer is on. To change computer batteries refer to the
computer manufacturers literature.

To preserve battery life, when not using the tester for an extended period of time, exit
MCEGold and shutdown the computer using the Windows shutdown feature.

Computer Ports
The parallel port on the back of the laptop computer is used to connect the computer to a
printer or a desktop PC. It is also used to connect the commutator bar-to-bar test leads to
the computer or the remote RIC cable.

The serial port on the back of the laptop computer is used to connect the computer to the
MCE board of the tester.

The PCMCIA slot on the laptop computer is used to support a DAQ (data acquisition)
card that connects the computer to the EMAX board of the tester. The PCMCIA slot can
also be used for a fax/modem card or a network connection. Additional PCMCIA cards
connected to the computer may cause a conflict with EMAX.

Tester Care and Handling

Refer to the computer manufacturers literature, supplied with the tester, for specific
information on operation, specifications, and maintenance of the laptop computer.

Tester Batteries charge immediately after use only if you will be using the tester in the
next two to three days; do not completely discharge; do not drop; do not incinerate; do not
short positive and negative terminals together; do not use in any other equipment; store
out of direct sunlight and away from extreme heat. See page 2-6 for more information.

Tester Battery Charger handle with care; follow instructions in the manual that came
with the charger.

Case Preventive maintenance consists of cleaning the unit with a mild detergent and
water, and visual inspection of the unit, test leads, and attachments.

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When cleaning the unit and/or deck, avoid spraying or pouring detergent or water directly
on the unit and/or test leads. It is recommended that you spray a reasonable amount of
mild detergent on a soft cloth and wipe the unit with the cloth. Then remove any detergent
residue with a clean soft damp cloth.

There are not any serviceable parts inside the unit. However, when inspecting the unit, test
leads, or attachment, search for broken parts, cracked wire insulation, and/or exposed
wires. DO NOT use damaged equipment. If defects are found, contact PdMA immediately
to arrange for repairs or replacement of the defective part. See Chapter One, Returning the
Tester to PdMA, for information regarding contacting PdMA.

Tester Environmental Conditions

Designed for indoor use

Operating temperatures: 41 F to 95 F (5 C to 35 C)

Storage temperatures: -4 F to 104 F (-20 C to 40 C)

Humidity: 20% - 80% non-condensing

Storage
Store the laptop computer in the ABS plastic case

Store the tester in the shipping case

Shipping
When returning the tester to PdMA for annual calibration, upgrades, or repair, follow the
procedure at the end of Chapter One, Returning the Tester to PdMA.

Accessory Bag
Accessories
The tester accessory bag, shown in Figure 2-5, is designed to carry supporting equipment
needed for motor testing that is not part of the tester itself. The gray nylon bag has black
trim and handles with a detachable shoulder strap.

On the outside of the bag are pockets for paperwork storage. On the front there is one large
pocket with a flap secured with Velcro. The flap is embossed with the PdMA Corporation
logo. On the front of the pocket is a clear plastic pouch which can be used for
identification. The back has a pocket without the flap.

The interior of the bag is divided into two sections secured with zippers. The front section
contains two large pockets with Velcro flaps, one on the front and the other against the
dividing wall between the front and back sections. The back section contains four pockets,
of equal size, with Velcro flaps. Two of the pockets are against the dividing wall and two
pockets are against the back side.

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Figure 2-5: Accessory Bag

The exact accessories you have depends on your model of tester. This is determined by
when your tester is built and which options you purchased. A newer, fully loaded tester
includes the following accessories. Your tester may not have all of these accessories.

MCE test leads

DC commutator bar-to-bar test leads

EMAX test leads

Laptop computer AC to DC converter and power cord

Two tester batteries and battery charger

Spare laptop battery

MCE Test Leads

The MCE test lead cable connects to the MCE connector on the front of the unit. The cable
has four leads, which connect to the three phases of an AC motor (black, blue, red) and
circuit ground (green). When testing DC motors, only the black, blue, and green leads are
used. MCE test leads are shown in Figure 2-6.

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Figure 2-6: MCE Test Leads

DC Commutator Bar-to-Bar Test Leads

The DC commutator bar-to-bar test lead cables connect to the testers MCE connector.
Bar-to-bar test leads are available in either pistol grip or pencil probe styles. Either style
provides for resistance measurement in a 4-wire configuration to allow for maximum
accuracy.

DC bar-to-bar pistol grip test leads are shown on the right and pencil probe test leads are
shown on the left in Figure 2-7.

Figure 2-7: Bar-to-Bar Test Leads

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EMAX Test Leads

EMAX Voltage test leads contain fuses and are color coded black (phase 1), blue (phase
2), red (phase 3), and green (common). They connect to the voltage connector on the right
side of the tester deck. Figure 2-8 shows an EMAX Voltage test lead.

Figure 2-8: EMAX Voltage Test Leads

EMAX Current test leads consist of three individual current probes and are connected
through a 3 BNC to a DB 9 adaptor cable. The BNC side of the adaptor is color coded
black for Phase 1, blue for Phase 2, and red for Phase 3. The DB9 side of the adaptor cable
connects in the space provided on the right side of the tester deck.

When connecting the three clamp-on current probes to each phase of the three phase
motor, ensure that the arrows on the current probes point in the direction of the cables
leading to the motor.

NOTE: Current probes are sensitive to current flow direction. Follow the arrow prompt
located on the probe.

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Figure 2-9 shows EMAX Current test leads.

Figure 2-9: EMAX Current Test Leads

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Specifications
MCE
For the four basic MCE tests, the tester applies the following test signals:

Table 2-1: MCE Electrical Specifications

Item Description
Power Input Rating 6 VDC 6.0 Amp-Hour
Battery Type Nickel Metal Hydride (Ni-MH)
MCE Connector Max Polarization Index 5000 VDC @<2mA
Outputs
Resistance-to-Ground 5000 VDC @<2mA
Resistance Phase-to-Phase <6 VDC @1A
Inductance/Capacitance 10 VAC @300Hz or
1200Hz

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EMAX

Table 2-2: EMAX Electrical Specifications

Item Description
Power Input Rating 6 VDC 2.5A
Battery Type DR11 AA or Equivalent
Current Connector Max 3V RMS
Input
Voltage Connector Max 600 VAC
Fuse Type F/0.1A/500V/6x32mm
Voltage Probe Fuse Type F/0.5A/1000V/6x44mm
Current Probe Refer to the probe manufacturers docu-
mentation included with the EMAX unit.

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Hardware
Shipping Case
Table 2-3: Shipping Case Specifications

Item
Color
Material
Outside Dimension
(LxWxD)
Inside Dimension (LxWxD)
Inside Front pocket
Inside Back pocket
Weight - empty/full
Description
Gray
Lexan and Aluminum
22.5x18.5x18 inches
57.15x46.99x45.72 centimeters
18.5x5.5x12.5/19x8.75x12.5 inches
46.99x13.97x31.75/ centimeters
48.26x22.225x31.75 centimeters
35/75 pounds
15.826/34.02 kilogram

Tester Case
Table 2-4: Tester Case Specifications

Item Description
Color Black
Material ABS Resin
Outside Dimension (LxWxD) 18.5x14.5x6 inches
46.99x36.83x15 centimeters
Inside Dimension (LxWxD) 18x13x5 inches
45.72x33.02x12.7 centimeters
Computer Area Dimension 11x14x2 inches
(LxWxD) 27.94x35.56x5.08 centimeters
Weight, without computer 19 pounds
8.62 kilograms
Weight, with computer 23 pounds
10.43 kilograms

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