Test tools and

troubleshooting
electric motors Application Note

Troubleshooting is the systematic Non-contact voltage can be used to indicate if voltage

elimination of various parts of a detector is present in an insulated con-
system, process, or piece of ductor, or that a non-insulated
equipment to locate a malfunc- A non-contact voltage detector is metal part is energized (hot, live)
tioning part. To locate and cor- a test tool that gives a visual by a hot conductor touching an
rect a motor malfunction quickly, indication when voltage is pres- improperly grounded system or
troubleshooting is best performed ent in a conductor, or other metal part. Touching an energized
using the proper test tools. Dif- parts. The tester glows red if metal part can cause an electrical
ferent types of test tools are used voltage is present. The red glow shock.
depending on which part of the
system is being tested and what
information is required to isolate
the fault. For example, when
troubleshooting a motor and
motor control circuit the follow-
ing test tools can be used:
• Non-contact voltage detector
is used to determine if con- ON

ductors or any non-grounded

metal parts are energized
before touching them. 3Ø motor
• Digital multimeter (DMM) is
used to take basic resistance, OFF

voltage, and current measure-

ments.
• Clamp-on ammeter is used to
take current measurements
without opening the circuit.
• Megohmmeter is used to
detect insulation deterioration.
• Non-contact thermometer is Flexible connection
used to measure temperature to motor using rubber
in order to determine circuit or plastic covered
overloading, poor connections, conductors
or undersized conductors.
• Power quality analyzer is used Non-contact voltage detector
to measure for harmonics on
the line, transients, power used to check if conductors
interruptions and other circuit are energized
conditions that can cause
component and system faults.

From the Fluke Digital Library @ www.fluke.com/library

Digital multimeter (DMM) models also include special fea- such as testing for power loss
tures for taking minimum/maxi- from blown fuses, excessive cur-
A DMM is a test tool that meas- mum, and relative measurements rent levels from overloaded cir-
ures several different electrical and/or testing diodes and capac- cuits, and improper resistance
quantities, such as voltage, itors. A DMM is required when from damaged insulation or
resistance, or current. Some performing troubleshooting tasks equipment.

3 phase motor 480/277 V, Y connected – voltage measurement

Phase to Phase
L1 to L3 L1 to L2 L2 to L3

4
Measure AutoHOLD FAST MN MX LOGGING YES AutoHOLD FAST MN MX LOGGING YES AutoHOLD FAST MN MX LOGGING YES

L1 to L2, HOLD MIN MAX REL From HOLD MIN MAX REL HOLD MIN MAX REL

L1 to L3,
CANCEL
Hz % ms
SAVE
RANGE
NO

Power CANCEL
Hz % ms
SAVE
RANGE
NO CANCEL
Hz % ms
SAVE
RANGE
NO

and
SETUP
nS

F
Supply SETUP
nS

F
SETUP
nS

F
mV
ac+dc
C mV
ac+dc
C mV
ac+dc
C
L2 to L3 A A A

L1 L2 L3
V
ac+dc
mA V
ac+dc
mA V
ac+dc
mA
mV A mV A mV A
dB dB dB

V A V A V A
dB
mA dB
mA dB
mA
ac+dc ac+dc ac+dc

A A A
3 OFF
VIEW MEM
ac+dc

CLEAR MEM
OFF
VIEW MEM
ac+dc

CLEAR MEM
OFF
VIEW MEM
ac+dc

CLEAR MEM

Set DMM A
mA
COM
TEMPERATURE

V A
mA
COM
TEMPERATURE

V A
mA
COM
TEMPERATURE

for AC 10A MAX

FUSED
A

400mA
FUSED
CAT
1000V
10A MAX
FUSED
A

400mA
FUSED
CAT
1000V
10A MAX
FUSED
A

400mA
FUSED
CAT
1000V
5
Voltage Measure
L1 to Ground,
Voltage jack L2 to Ground,
Common jack and
L3 to Ground

Phase to Ground
L3 to Ground L2 to Ground L1 to Ground

On
7 AutoHOLD FAST MN MX LOGGING YES AutoHOLD FAST MN MX LOGGING YES AutoHOLD FAST MN MX LOGGING YES

HOLD MIN MAX REL HOLD MIN MAX REL HOLD MIN MAX REL

Close CANCEL SAVE NO CANCEL SAVE NO CANCEL SAVE NO

Disconnect Off SETUP

Hz % ms RANGE

SETUP
Hz % ms RANGE

SETUP
Hz % ms RANGE

nS nS nS

Cover 1 mV
ac+dc
C
F
mV
ac+dc
F
C mV
ac+dc
F
C
A A A
V
ac+dc
mA V
ac+dc
mA V
ac+dc
mA
Remove mV
dB
A mV
dB
A mV
dB
A

Lockout/ V
dB
A
mA
ac+dc
V
dB
A
mA
ac+dc
V
dB
A
mA
ac+dc

Tagout OFF
VIEW MEM
A
ac+dc
OFF
VIEW MEM
A
ac+dc
OFF
VIEW MEM
A
ac+dc

CLEAR MEM CLEAR MEM CLEAR MEM

TEMPERATURE TEMPERATURE TEMPERATURE

mA mA mA
A A COM V A A COM V A A COM V

6 10A MAX
FUSED 400mA
FUSED
CAT
1000V
10A MAX
FUSED 400mA
FUSED
CAT
1000V
10A MAX
FUSED 400mA
FUSED
CAT
1000V

Verify
Rating of
Overcurrent
Devices 2
Open
Disconnect
Cover

Motor

Starter
Red Test Lead
RESET

Black Test Lead

2 Fluke Corporation Test tools and troubleshooting electric motors

Clamp-on ammeter
A clamp-on ammeter is a test
tool that measures current in a
circuit by measuring the strength
of the magnetic field around a
conductor. Most clamp-on amme-
ters measure AC, others can
measure both AC and DC. The
clamp-on ammeter allows cur-
rent measurements without
opening a circuit. The jaws of a
clamp-on ammeter are opened
and enclose the conductor under
test. The measurement displayed
indicates the amount of current
drawn by loads connected to the
conductor.

Motor running current

From
Power
Supply

L1 L2 L3

Disconnect On

Motor

On

Off

To change direction
of motor rotation,
interchange any two
Clamp Meter reading
load conductors
Rated Motor Motor Motor
(power off) current under- fully over-
of motor loaded loaded loaded
20 A 9.5 A 20 A 22 A
Disconnect
Nameplate 0 % to 95 % to 105 % +
listed 95 % of 105 % of of listed
value listed listed value
value value

L1 L2 L3 L1 L2 L3 L1 L2 L3

3 Fluke Corporation Test tools and troubleshooting electric motors

Megohmmeter
A megohmmeter is a test tool
that detects insulation deteriora-
tion by measuring high resist-
ance values under high voltage
conditions. A megohmmeter
detects insulation failure or
potential failure of insulation
caused by excessive moisture,
dirt, heat, cold, corrosive vapors
or solids, vibration, and aging.

Starter L1 L2 L3 PE

From
Power
Supply

L1 L2 L3

Disconnect

ON

T2
Lockout/Tagout T1 Position
Disconnect RESET Position
OFF

T1 T2 T3 PE
1
Testing
Starter
and Cable

Conductors

T1
T2
T3
T3 Position
Red Test Lead

Black Test Lead

T1
2
Testing
Motor T1
Position
T2

T2
Position

T3

T3
Wye-connected Position
low voltage 3Ø Motor

Recommeded Minimum Resistance*

Motor Voltage Rating Minimum Acceptable
(from nameplate) Resistance
Less than 208 100,000 Ω
208 – 240 200,000 Ω
Stator Windings
240 – 600 300,000 Ω
600 – 1000 1 MΩ
1000 – 2400 2 MΩ
2400 – 5000 3 MΩ
* Values for motor windings at 40 °C

4 Fluke Corporation Test tools and troubleshooting electric motors

Non-contact thermometer Loose, corroded, or dirty electri-
A non-contact thermometer is a
test tool that measures tempera-
ture at a single point. Tempera-
ture is measured when
troubleshooting because the
resistance of most materials
change as the temperature of the
material changes. An increase in
temperature decreases the per-
formance of electrical equipment
and destroys insulation.
cal connections generate
unwanted resistance and heat.
The temperature rise at a con-
nection depends on the current
flowing through the connection
and the resistance of the con-
nection. A temperature rise of
85 °F above ambient temperature
indicates a fault that requires
routine maintenance. Routine
maintenance is performed so that
the problem is fixed before it
causes damage. A 100 °F
increase requires immediate
action. Immediate action involves
immediate shutting down of a
system and repairing the fault.
Resistance in a normal circuit
occurs at the load. Resistance in
a circuit that has poor connec-
tions, corrosion, or other high
resistance paths occurs at points
other than the load. Infrared
meter temperature measurements
prevent problems by locating
unwanted heat.

Take temperature reading

of areas above ambient temperature
Finding Temperature
Reading
On
What is the temperature Equipment Condition
reading if the temperature Temperature
of an area is 145 °F and Difference* Indication
the ambient temperature
is 60 °F? Off 45 Light load on circuit
1. T = Temperature reading 60 Heavy load on circuit
– Ambient reading 85 Possible problem.
T = 145 – 60 Schedule routine maintenance
T = 85 °F 100 Dangerous problem.
(Schedule routine
* In ° F
maintenance)

Aim meter at area

to be measured

Take ambient termperature

61
INFR
reading for reference
THER AR
MO ED
ME
TER

5 Fluke Corporation Test tools and troubleshooting electric motors

Power quality
analyzer
A power quality analyzer is
a test tool used to obtain
and record more valuable
troubleshooting data. They
can take all the basic
measurements that a DMM
can take, and also measure
harmonics, transients,
power, and other electrical
quantities and problems. Power
Quality
Meter

Voltage or current
harmonic selction

MANUFACTURER
PE-21 PLUSTM PREMIUM EFFICIENCY
ORD. NO. 1LA2864SE41 MAG. 21.8

TYPE RGZESDI FRAME 286T

SERVICE
HP 30.00 FACTOR 1.0 3 PH
AMPS 77.5 VOLTS 230
Current
RPM 1765 HERTZ 60
51-770-642

DATE
DUTY CONT 40¡ AMB. CODE
CLASS
INSUL
NEMA
H DESIGN KVA
B CODE G NOM, NEMA
EFF. 93.6
AC Supply
SH. END OPP. END
BRG. 50BC03JPP3 BRG. 50BC03JPP3

Inverter Duty AC Induction Motor

Made in U.S.A.

3Ø Motor

Fluke. Keeping your world

up and running.
This article is based on material
excerpted from Electric Motor Drive
Installation and Troubleshooting, Fluke Corporation
Troubleshooting Electric/Electronic PO Box 9090, Everett, WA USA 98206
Systems, 2nd Edition, Power Quality Fluke Europe B.V.
Measurement and Troubleshooting, and Electrical PO Box 1186, 5602 BD
Motor Controls, 2nd Edition published by American Eindhoven, The Netherlands
Technical Publishers, Inc. To obtain information on For more information call:
In the U.S.A. (800) 443-5853 or
related training products, visit the American Tech web Fax (425) 446-5116
site at www.go2atp.com. In Europe/M-East/Africa (31 40) 2 675 200 or
Fax (31 40) 2 675 222
In Canada (800) 36-FLUKE or
Fax (905) 890-6866
From other countries +1 (425) 446-5500 or
Fax +1 (425) 446-5116
Web access: http://www.fluke.com
©2003 Fluke Corporation. All rights reserved.
Printed in U.S.A. 8/2003 2105286 A-ENG-N Rev A
6 Fluke Corporation Test tools and troubleshooting electric motors