Stator vacuum tester is suitable for vacuum surge testing and other electrical performance testing of various motor stators. It is applied to refrigerator and air conditioner compressor motor stator, brushless motor stator, automobile motor stator, etc. All the project tests can be completed at one-stop.
Easy-to-operate: 19-inch LCD, User-friendly interface and each function interface come with help document.
High performance: support AC Hi-pot, insulation resistance, surge, DC winding resistance, rotation etc.
Strong adaptability: support to perform the surge test for winding over 10μH, and close loop voltage feedback makes the test more accurate.
Easy-to-maintain: support intelligent self-inspection, remote failure diagnosis, and online software upgrading. Insertable card design makes it easy to disassemble and replace.
High efficiency: all the tests can be done at one-stop with one wire connection.
Easy-to-use: Professional test software, User-friendly interface, built-in help documents, high-performance touch screen, and numeric keyboard as standard.
Multiple interfaces: the instrument comes with USB, LAN(can be converted to RS232, RS485, etc.)port, support TCP/IP network protocol, and PLC simulation technology. Instrument control and expansion are quite easy.
Language support: different language options to meet the needs of customers at home and abroad.
Intellectualization: the system can be connected to the external internet through the internet port to achieve data interaction and resource sharing, meeting the requirements of the new generation of the internet.
Modular card design: independent testing module card, difference function has difference card.
Test items: AC Hi-pot, insulation resistance, surge, DC winding resistance, inductance, reverse embedded wiring, rotation.
Stator vacuum tester adopts air and negative pressure technology, one-stop fast test motor stator.
Parallel serial testing can be selected for higher efficiency.
Vacuum degree setting range
Motor stator (compressor motor, BLDC motor, automotive motor, AC induction motor)
Output voltage setting range/precision
Breakdown current test range/precision
0.10～20.00mA ±(2%×display value+0.05mA)
Breakdown current preset alarm range
Upper limited：0.10～20.00mA；Lower limited：0.00～20.00mA
Test time range/ resolution
1~9 level（9 is the most sensitive level）
Insulation resistance measurement range/ precision
1～500MΩ ≤100MΩ：±(3%×display value+0.5MΩ)； >100MΩ：±(5%×display value +5MΩ)
Insulation resistance alarm setting range
Upper limited：0～500MΩ；lower limited：1～500MΩ
Test time range/ resolution
Output voltage setting range/precision
500～3000V/5000V ±(3% * display value +8V)
Area, area difference, corona and phase; test screen show three or six surge waveforms (surge positive and negative hit)
DC resistance test
10.0mΩ～20KΩ ±(0.3%×display value+3digits) temperature compensation can be set
Test time range/resolution
Temperature measuring range/precision
Electrical level (voltage)
Reverse embedded wiring
Reverse embedded wiring judgment
Detects if there is an incorrect embedding of the top, bottom, or left or right of the wire pack
Wire wrapping anti-inlay >5%
CW, CCW, Still
A stator vacuum test is a diagnostic procedure performed on electric motor stators to assess the integrity of their insulation system. It involves subjecting the stator windings to a low-pressure or vacuum environment to detect potential faults or weaknesses in the insulation.
During a stator vacuum test, the motor is typically placed inside a vacuum chamber or enclosure, and the air is evacuated to create a low-pressure environment. The vacuum level is carefully controlled and monitored throughout the test.
The purpose of the stator vacuum test is to detect insulation breakdowns, cracks, voids, or other faults that may not be easily visible or detectable under normal atmospheric conditions. The low-pressure environment can reveal defects in the insulation system that could lead to insulation breakdown, reduced dielectric strength, or other issues impacting motor performance and reliability.
Various indicators can be observed during a stator vacuum test, such as changes in pressure, corona activity, or other electrical phenomena. These observations can provide valuable diagnostic information about the condition of the stator windings and guide further maintenance or repair actions.
It's important to note that the specific procedures, equipment, and standards for stator vacuum testing may vary depending on the industry, motor type, and specific requirements. Manufacturers or industry guidelines typically provide detailed instructions and specifications for conducting stator vacuum tests.
Stator vacuum testing can offer several advantages in the field of electric motor maintenance and repair. Here are some potential benefits of utilizing stator vacuum testing:
·Insulation fault detection: Vacuum testing can help identify insulation faults or weaknesses in the stator windings that may not be easily detectable under normal atmospheric conditions. By subjecting the stator to a vacuum, any cracks, voids, or insulation breakdowns can be revealed, allowing for timely repairs or replacements to prevent motor failures.
·Moisture detection: Vacuum testing can detect the presence of moisture or other contaminants within the stator windings. Moisture ingress can lead to insulation deterioration and reduced motor performance. By creating a low-pressure environment, vacuum testing can reveal any trapped moisture, helping to identify potential issues and take appropriate corrective measures.
·Improved testing sensitivity: Vacuum testing increases the sensitivity of fault detection. Under vacuum conditions, even small faults or weak spots in the stator insulation can be more easily detected compared to testing at atmospheric pressure. This can help identify potential problems at an early stage, allowing for proactive maintenance and reducing the risk of unexpected failures.
·Quality assurance: Vacuum testing can be employed during the manufacturing process as a quality control measure. By subjecting newly manufactured stators to vacuum conditions, any manufacturing defects or insulation weaknesses can be detected before the motors are put into service. This helps ensure that only stators with reliable insulation are utilized, improving overall motor quality and reliability.
·Preventive maintenance: Vacuum testing can be part of a preventive maintenance program for electric motors. By periodically subjecting the stator windings to vacuum conditions, any insulation degradation or weaknesses can be detected in advance. This allows for proactive repairs or replacements, reducing the risk of unexpected motor failures and minimizing downtime.
·Diagnostic capabilities: Vacuum testing can provide valuable diagnostic information about the condition of the stator windings. By observing pressure changes, corona activity, or other indicators during the test, potential issues such as insulation breakdown, contamination, or manufacturing defects can be identified. This information can guide further troubleshooting or maintenance actions.
- Ensure that the stator to be tested is disconnected from any power source and properly isolated.
- Inspect the stator for any visible damage, loose connections, or signs of moisture.
- Set up the vacuum testing equipment according to the manufacturer's instructions. This may involve connecting the vacuum chamber or enclosure to the testing apparatus, such as a vacuum pump and pressure monitoring devices.
·Sealing and evacuation:
- Position the stator within the vacuum chamber or enclosure, ensuring that it is properly secured and positioned for testing.
- Seal the chamber or enclosure around the stator to create an airtight environment.
- Begin the evacuation process using the vacuum pump to remove air from the chamber. Gradually reduce the pressure to the desired level, typically specified by the manufacturer or industry standards.
·Pressure monitoring and observation:
- Monitor the pressure levels within the chamber using the pressure monitoring devices or gauges.
- Observe the stator for any observable changes, such as visible corona discharge, sparking, or pressure differentials.
- Pay attention to any specific indicators or measurements provided by the vacuum tester equipment, such as changes in the pressure or electrical activity.
·Test completion and venting:
Once the testing period is completed, follow the recommended procedures for venting the vacuum chamber. Release the vacuum gradually and safely to avoid sudden pressure changes or damage to the stator windings.
Disconnect the stator from the vacuum testing equipment and inspect it for any visible signs of damage or changes.
It's important to note that the specific testing parameters, such as the duration of the test, pressure levels, and observation criteria, may vary depending on the motor type, industry standards, and the equipment being used. Always refer to the manufacturer's instructions and any applicable industry guidelines for detailed and accurate procedures when performing stator vacuum testing.
When using a stator vacuum tester, it's important to follow certain precautions to ensure safety and accurate testing results. Here are some general precautions to consider:
·Familiarize yourself with the equipment: Before using a stator vacuum tester, thoroughly read and understand the manufacturer's instructions and operating manual. Make sure you are familiar with the specific features, capabilities, and limitations of the equipment.
·Personal protective equipment (PPE): Wear appropriate personal protective equipment, such as safety glasses, gloves, and any other recommended gear, to protect yourself from potential hazards during the testing process.
·Electrical safety: Ensure that the stator being tested is properly disconnected from any power source to prevent electrical shock. Follow standard electrical safety practices, such as lockout/tagout procedures, when working with electric motors or generators.
·Vacuum chamber integrity: Inspect the vacuum chamber or enclosure for any signs of damage or leaks before conducting the test. A compromised chamber may affect the accuracy of the results or pose safety risks. Ensure that all connections, seals, and valves are in good condition and properly secured.
·Pressure monitoring: During the vacuum test, closely monitor the pressure levels within the chamber to ensure they remain within the specified range. Excessive pressure differentials or sudden pressure changes could indicate a potential issue with the stator or the testing equipment.
·Venting procedures: Establish proper procedures for venting the vacuum chamber after the test. Release the vacuum gradually and safely to avoid sudden pressure changes that could damage the stator windings or affect the surrounding environment.
·Proper grounding: Ensure that the stator being tested and the vacuum testing equipment are properly grounded to minimize the risk of static electricity buildup or discharge.
·Qualified personnel: Vacuum testing of stators should ideally be performed by qualified personnel who have the necessary knowledge and training in motor diagnostics and electrical safety practices.
Testing motor stators under vacuum can be beneficial for several reasons, primarily to assess the insulation integrity of the stator windings. Here are a few reasons why vacuum testing may be performed:
·Insulation breakdown detection: Vacuum testing can help identify any weaknesses or faults in the stator winding insulation. Under vacuum conditions, any cracks, voids, or insulation breakdowns that may not be visible or apparent under normal atmospheric conditions can be revealed. This type of testing is particularly useful for detecting partial discharges or corona activity, which can be indicators of insulation failures.
·Moisture ingress detection: Vacuum testing can help detect the presence of moisture or other contaminants within the stator windings. Moisture ingress can lead to insulation degradation, reduced dielectric strength, and potential motor failures. By subjecting the stator windings to a vacuum, any trapped moisture or contaminants can be detected, helping to identify potential issues before they escalate.
·Quality control and manufacturing assessment: Vacuum testing can be used during the manufacturing process to ensure the quality and reliability of the stator windings. By subjecting newly manufactured stators to vacuum conditions, any manufacturing defects or insulation weaknesses can be identified before the motor is put into service.
·Preventive maintenance: Vacuum testing can be part of a preventive maintenance program for electric motors. By periodically subjecting the stator windings to vacuum conditions, any insulation degradation or weaknesses can be detected early, allowing for timely repairs or replacements. This can help prevent unexpected motor failures and minimize downtime.
It's important to note that while vacuum testing can be a valuable diagnostic tool, it is not the only method used for assessing stator insulation integrity. Other techniques such as insulation resistance testing, surge testing, or high-potential (hi-pot) testing may also be employed depending on the specific requirements and standards of the industry.