Dos
1. Power Supply to the motor under
test should be switched off before
testing. (Removal of the fuses is
the best method for isolation).
2. Test Clips should be connected
at the correct terminals of each
winding on the motor.
3. While measuring the Resistance
or inductance, choose the proper
range
4. Take the measurements in the
following order.
a) Insulation resistance between any
terminal to the earth.
b) Resistance of the stator windings.
c) Inductance of the stator windings.
d) Inductance of the stator with respect
to the various incremental positions
of the rotor, in steps of 10° .
12
DON’Ts Digital Motor Checker EMC - 38
1. Do not expose the instrument to
continuous direct sunlight / Rain
or excess humid conditions.
2. Do not subject the instrument to
excessive shock or vibrations.
3. Do not open / handle the instrument
when ever the instrument malfunctions
4. Avoid using the instrument when
the temperature of the
Surrounding is more than 55°C
5. Do not Test the Motor without
Isolating its power
6. Avoid using the instrument when
the display shows “ LOWBAT”
INTRODUCTION:
EMC -38 provides a fast and easy means to detect electrical faults-
short circuits, open circuits, damaged insulation etc. – in motors and
other three phase machine.
EMC -38 IS USED ON STATIONARY MOTORS. THE MOTOR HAS
TO BE ISOLATED FROM ITS POWER SUPPLY BEFORE TESTING.
There is no need to disconnect the supply cables provided the power
is switched off. Readings can be taken at any connecting point along
the motor power supply cables. The basic test can be made on site,
without disconnecting the phase windings.
THE BASIC TEST
On any three-phase machine, an electrical fault can be detected by
1) measuring insulation resistance to earth
2) measuring and comparing the resistance of the stator windings
3) measuring and comparing the inductance of the stator windings
and the effected of the rotor position.
Resistance and inductance VALUES OF EACH PHASE ARE
MEASURED AND COMPARED WITH EACH OTHER. They should be
identical or differences should be within acceptable tolerance limits.
Measurements should be made in the above order. The sequence can
be interrupted as soon as a fault is detected.
TOLERANCES
There are no internationally agreed standards for acceptable and
unacceptable conditions in electric motors. Tolerance on insulation,
resistance and inductance vary between manufacturers and even
between individual motors of the same type and size. They should not,
however, exceed certain limits.
INSULATION RESISTANCE BELOW 1 MEGOHM ARE REGARDED
AS DANGEROUS. THE MOTOR SHOULD NOT BE USED.
New motors in the smaller size ranges ( below 10Kw ) normally have
1
 of the rotor whe re ’p’ is the
would vary widely ‘p’ num-
than the value (inductance)

ber of times per revolution

no. of poles of the motor

If a cage bar crack exists

Data is based on experience and should be used as a guideline only. RY, RN etc., indicates measured values of inductance and resistance
Less than 5% differences between individual phase winding resistances
and inductances. On large motors ( above 100Kw ) difference of up to 10%
can be acceptable.

Like ly defective
section
FAULT ANALYSIS

A difference in the resistance and /or inductance of individual windings

which is greater than 10% will indicate a fault in any motor. The 10% limit
has therefore been used throughout this manual. Smaller deviations have
to be judged by the user with regard to both the size and the application of
the motor.

If variations
be taken based more than
Reject

on the test condi- 15%

Note that resistance and Inductance readings on motors connected in star
or delta will show approx half the effect of a fault in a single winding. Thus,

with the use of motor

with the use of motor

Decision to be taken
a spread of more than 5% measured on a connected motor, corresponds

experience gained
conditions and the
experience gained

based on the test

to a deviation by more than 10% in an individual winding i.e. exceed in the

tester EMC-38
tester EMC-38
tolerance limit.

tions and the

Decision to
Difference
MOTOR CONDITION SHOULD ALSO BE STABLE WITH TIME.

Warning
CHANGES IN ANY OF THE PARAMETERS OCCURING BETWEEN ONE
MEASUREMENT & THE NEXT WILL INDICATE THE DEVELOPMENT OF
A FAULT.

FAULT ANALYSIS:

of balance Accept

AS the rotor Less

than
5%
If required, the nature of a single fault can be determined by disconnecting

11
measuring and comparing individual phase winding.

and interpret the results as usual

sign of health

Check as a single speed motor

Condition

very slowly

which is a
the values
Large differences in resistance only indicate an open circuit in one of the

very little
is rotated

in that particular connection

fluctuate
several parallel coils which make up the stator winding. Or high resistance

motor
in a contact because of looseness, dirt or sparking damage. CHECK FOR
PROPER CONTACT BEFORE DISMOUNTING THE MOTOR.

Large differences in inductance only are probably cause by an inter turn

Measure
Between

or BR any
one of the
RY or YB
short circuit in a stator winding. AS THE DAMAGE SPREADS IT WILL

windings
ALSO AFFECT RESISTANCE READINGS.

phase
A ROTOR FAULT WILL AFFECT THE INDUCTANCE OF THE STATOR
WINDING AS ROTOR POSITION IS CHANGED.

Configuration

between the said terminal.

In case of two
speed motors
2
Sl.No

6
 Other in any section, if the
Value is higher than other
USING THE INSTRUMENT

Short in the lower value

other two equal values.

to the other two values
Lower value compared

section if compared to
would indicate a short
☞ CAUTION
Likely defective

In the lower section

Two equal values

section

● Isolate the motor from its power supply before testing

● Insulation resistance is tested with 500 V/1000V DC, current 0.25 mA. .Max

BATTERY TEST

Set the FUNCTION switch to BATTERY TEST. Press the operating

button. If the instrument shows “LO BAT” Symbol replace the

Decision to be taken More

Reject

than
12%
batteries.
Decision to be taken More
than
12%

experience gained with

the use of Motor tester
TEST OF INSULATION RESISTANCE
experience gained
conditions and the

based on the test

conditions and the
based on the test
Difference

with the use of

Set the FUNCTION switch to INSULATION. Connect the test leads to

Warning

the terminals marked INSULATION 500V.& 1000V

Motor tester

EMC-38
EMC-38

On star or delta connected motors, connect one test clip to a suitable

earth point on the machine frame and the other clip to one of the
winding terminals.
of balance Accept

than
Less

Press the operating button, Measure the insulation resistance of phase

5%
Less
than
5%

10
windings to earth.
Condition

Insulation resistance in excess of 2 Meg ohm are normally acceptable.

RY=YB=

Values below 1 Meg ohm can be dangerous and the motor should not
RY=YB=

be used. In this case, further tests with the EMC-38 are not necessary
BR
BR

and the motor requires maintenance.

Measure
Between

RY/YB/
RY/YB/

BR
BR

3
Configuration
Sl.No

4
3
 short if RN is lower than
USING THE INSTRUMENT (Continued )

YB then a or b is Short
defective winding is RN
to the other two values
Lower value compared

higher than the other

If RY=RB is less than

. than YB then a or b
would indicate a short

open Circuit. If RY-RB

Likely defective

If RY=R RB is more
vice versa for open
and vice versa for an

a or b open if RN is

two YN=BN a or b
In the lower section

is less than YB then

with a short or vice

If stator windings are not interconnected one can test the insulation

section
resistance to earth of each winding separately, and also test the insulation

the other two.

versa for open.
between windings.

is open.
NOTE: For battery test and insulation Resistance measurements the
RANGE switch position has no effect.

MEASURING AND COMPARING RESISTANCE

than 12%

Decision to be taken Mo re

More
Reject
INTERPRETATION CHART for Resistance and Inductance

than
20%

12%
than
More
Set the FUNCTION switch to RESISTANCE. Connect the test leads to the

Decision to be taken More

than
20%
terminals marked RESISTANCE / INDUCTANCE.

experience gained with

the use of Motor tester
ON CONNECTED MOTORS (star or delta): Connect the test clips to two of

conditions and the

based on the test
experience gained
conditions and the
based on the test
Difference
the supply terminals (R-Y).Press the operating button. Adjust the range

with the use of

switch to obtain the largest possible reading on display screen. Record the

Warning

Motor tester
reading shown on the display screen of the meter and the Range chosen.

EMC-38
EMC-38
Without altering the setting of the RANGE switch, repeat the measurement
across the other two pairs of supply terminals (R-B, Y-B).

of balance Accept
Compare the readings: Ideally there should be no difference between the

than 5%

10%

10%
9 Less
Less
than

than
Less
readings. Differences of less than 5% w.r.t. lowest reading can be within

than

Less
10%
acceptable tolerance: see Interpretation Chart.

9
Condition
On disconnected motors: Connect the test clips to the phase winding

RN=BN=
RN=BN=

RY=YB=
terminals ( R-R₁, etc). Measure and compare as above. Difference of less

RY=YB
than 10% can be within tolerance limits.

BR

YN

BR
YN
MEASURING AND COMPARING INDUCTANCE

Measure
Between

RY/YB/
Leave the test leads connected to the terminals INDUCTANCE /

RY/YB/

RN/BN/
RN/BN/
RESISTANCE.

BR
BR

YN
YN
Set the FUNCTION switch to INDUCTANCE.

Configuration
The rotor must be stationary while measuring inductance. The measuring
procedure is the same as for resistance measurement. First adjust the
RANGE switch to obtain the correct reading on the display screen, but do
not alter its setting between subsequent readings.

4 Sl.No

2
☞ TECHNICAL DATA
USING THE INSTRUMENT (Continued)
Measuring range
On connected motors : take three readings across the supply
Insulation : 0 – 200 M ohms at 500 V DC, 0.25 mA Max. terminals ( R-Y, R-B, Y-B ). The difference should be less than 5%
0 – 2000 M Ohms at 1000V DC, 0.25 mA Max. w.r.t. largest reading.

Resistance : 0 –200 ohms. (In 4 ranges) On disconnected motors: measure across each phase winding (R -
R₁, Y - Y₁, B – B₁ ). The readings should not differ by more than
Inductance : 0 – 2000 mH (In 4 range ) 10% of the largest reading-see interpretation chart.

Battery Test : Condition of batteries indicated on display. Equal readings, or small difference within the tolerance limits,
indicated that both stator and rotor are in good condition. If the motor
Power source : 6 X AA size (Alkaline) cells. condition is still suspected, turn the rotor approx. 90°C and repeat the
measurement.
Dimensions : 210 x 125 x 65 mm
Note: For obtaining the approximate resistance and inductance
Operating temperature : 0 - 55°C values, note the reading obtained and the range selected. From the
Range chart calculate the value.
Weight : 1000 Grams
Rotor Test:

TECHNICAL DATA ARE SUBJECT TO CHANGE WITHOUT NOTICE.
☞ RANGE CHART
Considerable differences between inductance readings can be due to
Either stator or rotor faults. A fault in one of the stator winding will
show as a difference in the reading for that winding as compared with
the other two, independent of rotor position. A rotor fault will alter the
inductance in any one of the windings as the rotor position is changed.

Disconnect and measure across a single phase winding ( R - R₁).

Then turn the rotor 10 - 20° and measure again. Repeat this procedure
POSITION OF RESISTANCE INDUCTANCE several turns. Until sure. That the readings remain stable or that there
are large changes with rotor position.
RANGE SWITCH OHMS (FSR) mH ( FSR)
A single fault in the rotor should cause the reading to rise and fall “P”
1 200 2000 times per revolution, Where “P” is the number of poles in the motor.
Small, regular variations in the readings are due to the position of
2 20 200 individual cage bars and can be disregarded- See interpretation chart.
3 2 20
Various Applications
4 200 milli Ohms 2
The measuring procedure as described above applies directly to
squirrel case induction motors, the most common type of motor used
in industry. However, the measuring principle of comparing the
resistance and inductance of individual windings can be applied to
8
5

5
 Any three phase machine which has a series of identical coils with in
the measuring range of EMC -38. This includes synchronous motors,
transformers, generators, alternators etc.

Wound rotor induction motors:

Both the stator and the rotor of these motors can be tested following
6 the standard procedure. Rotor winding resistance should be measured
from the slip rings to avoid any inconsistency in the readings due to
6 carbon brushes.
1
1 Multiple speed motors:

2 2 Motors with any type of electronic speed control should be measured

as the corresponding single speed motor, provided there is no shunt or
series capacitance between the measuring point and the motor
3 3 winding.

4 4 Power factor correction capacitors:

5
Power factor correction devices should always be disconnected before
5 the test. They will mask significant differences in measured inductance
and therefore should not be retained in the measuring circuit.

Single Phase motors:

On commutator motors one can check the balance of the rotor and
compare different rotor segments.

EMC -38 can also be used to measure changes in stator resistance

1. Instrument display 4. Function switch
and inductance with time and thus follow the trend of deterioration
2. Operating button. 5. Range switch from new or good condition.

For production line testing, components are measured against a set of

3. 500V / 1000V Selection switch 6. Terminals for test leads
norm values from known good components.

6 7
 Digital Motor Checker
EMC-38

CONTENTS

Operating Principle ……………………… 01

Using the Instrument …………………… 03

Various applications ……………………. 05

Technical data …………………………… 08

Range Chart ……………………………… 08

Interpretation Chart ……………………. 09

Dos and DON ’Ts ………………………. 12

 MCM Instruments

Digital Motor Checker EMC-38

MCM INSTRUMENTS
(An ISO 9001:2008 Certified Company)
Plot No: 82, “MCM BHAVAN”, Sai Anurag Colony, Bachupally,
RR Dist.- 500 090, Telangana, India.
Tel: +91 40 64547744, Mob: +91 9542316737, +91 9440845436
Email:info@mcminstruments.com/mcm_instrument@yahoo.co.in Instructions for use
www.mcminstruments.com
MCM INSTRUMENTS
Madinaguda,
Hyderabad – 49
Ph: 040 – 23046334
 Do not operate the function and range switches when the
push to on switch is pressed.

 Select oppropriate range and function before pressing

the push to on switch.

 Do not mix old and new cells, If you are using the
dry cells.

 Clean the terminals before connecting the test leads

(Eg : grease, paint or corrosion ) to avoid erratic readings.

 Insulation Resistance (IR):When measured 1000 V DC,

do not measure other functions immediately, as Voltage
may be present in the motor