A surge test or hipot test failure above operating voltage means that the motor

should be scheduled for recondition or replacement, but it does not have to be taken
out immediately. A DC hipot or surge test failure is not damaging to the windings if
the tests are done according to instructions and standards. 

IMAGE 2: PDIV chart

The PD measurement provides the earliest indicator of insulation breakdown. It’s

best used as a predictive maintenance tool to trend measurements over time. If the
voltage at which PD is first detected—known as the repetitive PD inception voltage
(RPDIV)— declines over a period of time, this may indicate insulation breakdown
(Image 2).  

Motor Data
Testing motors generates a large amount of data, so data storage and analytics is an
important part of the job. Some facilities have hundreds, if not thousands, of motors
under management. In addition to the test results, asset managers need a tester that
can import and store motor data such as motor ID number, asset number,
location/description and other motor specifications.  

Reporting
Advanced static testers generate reports and allow users to view test summaries in
standard reporting software. With Excel or other spreadsheet and database
software, trend analysis shows gradual changes in insulation systems and helps
users identify issues before it is too late. Additionally, comparison of groups of
motors with similar specifications is possible so “bad apples” stand out and can be
addressed. 

Portability
Not all motors can be tested from a central location. Advanced static motor testers
are portable and have a rugged, self-contained case. They are built for testing a wide
range of motors in facility or field applications. For higher voltages, portability
becomes more critical. Power packs are available that are controlled by the tester
and can boost testing voltages up to 40 kilovolt (kV).   
    
Wide Range of Tests
Depending on the types and motors in use, testing voltages can range greatly.
Alternating current (AC) motors, DC 
motors, generators and a selection of transformers can be tested offline. In addition
to the overvoltage tests mentioned above, static motor testing can also include low
voltage tests to give a more complete picture of a motor’s insulation health.

Other tests include:

 insulation resistance: egohm, dielectric absorption ratio (DAR), polarization

index (PI) 
 winding resistance measurements
 capacitance, inductance, impedance and phase angle measurements
 rotor influence check (RIC) test to find squirrel cage rotor issues 

Test From the MCC

For facilities with a motor control center (MCC), motors can be tested directly
through the power cables from a remote location. There are several caveats,
however.