Page 1 D30R Users Manual Users Manual Digital Surge/DC HiPot/Resistance Tester Models D30R Baker Instrument Company 4812 McMurry Avenue Fort Collins, CO 80525 (970) 282-1200 (970) 282-1010 FAX (800) 752-8272 USA Only www.bakerinst.com Do Not Touch Test Leads while test is in Progress!
Page 2 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 3: Warranty
There are no warranties which extend beyond those expressly stated in this contract. If within one year of shipment by Baker of any item of the product, purchaser discovers that such item was not as warranted and promptly notifies Baker in writing thereof, company shall remedy such non conformance by, at company’s...
Page 4 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 5: Table Of Contents
D30R Users Manual Table of Contents Warranty ...................... 3 PREFACE......................9 ..................11 AFETY RECAUTIONS ............... 11 OWER OURCE RECAUTIONS .................. 12 ROUND THE RODUCT & S ..................12 ERMS YMBOLS ..................12 ARRANTY OTES Important notice concerning the Warranty and Repairs......12 ..............
Page 6 D30R Users Manual Auto Ranging Resistance Measurement Algorithm........37 Saving & Recalling Measurements ............37 Indications of problems in a motor ............38 CHAPTER 4: PRINCIPLES & THEORY OF DC TESTING ....39 DC T ................41 RINCIPLES OF ESTING CHAPTER 5: PERFORMING HIGH VOLTAGE DC TESTS ....
Page 7 D30R Users Manual ................. 83 AINTENANCE ESTING Application Notes..................84 ......... 85 INGLE HASE OTORS AND ERMINAL EVICES Determination of a Fault................85 ....................86 OILS Determination of a Fault................86 Notes and Tips for Form Coils............... 86 .................. 87...
Page 8 D30R Users Manual Recall Resistance Data ................113 Recall HiPot Data..................114 Recall Surge Data ..................115 Recall Lead Submenu Options ..............115 Print ......................116 Clear ......................116 Erase ......................116 ............117 OMPATIBLE RINTER NFORMATION Version 3 Firmware ................. 117 APPENDIX A: TYPICAL WINDING FAULTS ........
Page 9: Preface
D30R Users Manual REFACE Inside… • Safety Precautions • Power Source Precautions • Ground the Product • Terms and Symbols • Warranty Notes • Authorized Service Centers • Training Seminars • Environment • Shipment • List of Items Furnished Do Not Touch Test Leads while test is in Progress!
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Page 11: Safety Precautions
D30R Users Manual Safety Precautions Note: The general safety information presented here is for both operating and service personnel. Specific warnings and cautions will be found throughout this manual where they apply. DANGER High-voltage test equipment should be handled with CAUTION.
Page 12: Ground The Product
Shipment section at the end of this chapter. Also, be sure to complete the Warranty Return Form when sending the tester to Baker Instrument Company. Do Not Touch Test Leads while test is in Progress!
Page 13: Authorized Service Centers
D30R Users Manual If there is a failure of the Baker tester, regardless of whether it is under warranty or not, the customer should Call the Baker Instrument Company Service Department BEFORE returning the unit for repair. In some cases, the repair may be done by the customer at significant savings.
Page 14: Shipment
D30R is NOT approved for use in an explosive environment. Shipment All Baker testers are shipped using factory foam-filled containers. Should the tester be returned to Baker Instrument Company for any reason, we recommend using the original packaging the unit came in or the following factory specified packaging: Contact Baker Instrument Company to order factory-specified packaging for the testers.
Page 15: Chapter 2: Instrument Overview
D30R Users Manual 2: I HAPTER NSTRUMENT VERVIEW Inside….. • Front Panel Controls • Initial Tester Power Up & Checkout Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 16 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 17 D30R Users Manual D30R Digital Front Panel Diagram Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 18: Front Panel Controls
D30R Users Manual Front Panel Controls 1) PRINTER PORT Parallel port for printing waveforms and summaries displayed by the Digital Tester. This port may also be used for interfacing with the Motor Test Acquisition for Windows program (MTA for Windows) on a personal computer.
Page 19 CRT for reference. There are four primary position as follows. • AUX: The auxiliary position is for the D30R is used for Surge and HiPot modes. • SURGE: This position selects the Surge Test. The name of the test and the microseconds per division measured is displayed on the lower portion of the CRT for reference.
Page 20 D30R Users Manual of the test and the resultant resistance in mega-ohms is also displayed on the screen for reference. There are three positions associated with the HiPot test. The three positions are 100uA/div, 10uA/div, and 1uA/div. The chosen micro-amps per division...
Page 21 D30R Users Manual 15) OUTPUT CONTROL This control adjusts the output voltage of the tester. Clockwise (CW) rotation increases output and counterclockwise (CCW) rotation decreased output. Full CCW is the MIN (minimum) point output and full CW is MAX (maximum) or 100% of the testers rated output.
Page 22: Initial Power-Up And Check-Out
21) Kelvin Resistance Test Leads Initial Power-Up and Check-Out Note: Each Baker Instrument Company Tester incorporates a supply ground detection circuit. This circuit assures a positive grounding of the tester. If the instrument is not properly ground , the OPEN GRN indication will light and testing cannot proceed.
Page 23: Chapter 2: Recommended Test Sequence, Voltages And Testing Precautions
D30R Users Manual 2: R HAPTER ECOMMENDED EQUENCE OLTAGES AND ESTING RECAUTIONS Inside…. • Recommended Test Sequence • Coil Resistance • Megohm Test • Dielectric Absorption (DA) • Polarization Index (PI) • DC HiPot • Surge • Recommended Test Voltage DC HiPot & Surge •...
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Page 25: Recommended Testing Sequence
Recommended Testing Sequence In order to test motors adequately and to have effective predictive maintenance programs, Baker Instrument Company suggests using a specific test sequence. The general idea is to perform the test sequence as a series of progressively more rigorous tests, accepting the idea that if a test fails, troubleshooting and repair should begin at that time.
Page 26: Principles Of The Dielectric Absorption (Da) Test
D30R Users Manual 3. Principles of the Dielectric Absorption (DA) Test The Dielectric Absorption (DA) Test is essentially a short-duration PI test and is usually intended for smaller motors. Larger motors whose insulation does not easily polarize are also good candidates for the DA Test. Other than the shorter test time, all other principles are the same as the PI test, explained in the next section.
Page 27: Dc Hipot Test
D30R Users Manual Unfortunately, most the insulating materials developed recently (last 20 years) do not easily polarize. For example the newer inverter grade wires and epoxy resins do not readily polarize. As recommended in IEEE 43-2000, if the one- minute insulation resistance is greater than 5000Mohms, the PI measurement may not be meaningful.
Page 28: Recommended Test Voltages - Dc Hipot And Surge Tests
IEEE 43-2000 (test voltages less than 5000V). View the enclosed tables for a comparison of IEEE 95, EASA DC HiPot, IEEE 522 Surge Testing, IEC 34-15 & Baker recommended testing voltages. Note: Representations of motors are listed. The formulas to calculate voltages are also listed so that test voltage on any size motor can be calculated.
Page 29: Iec 34-15
D30R Users Manual IEEE 522 Surge Testing V Line Per Unit New 3.5* pu In Service 75% of New 1372 1029 1643 1232 1715 1286 2300 1878 6573 4930 4160 3397 11888 8916 6900 5634 19718 14789 13800 11268 39437...
Page 30 D30R Users Manual IEC 60034-1 (1999-08) Consolidated Edition, Rotating Electrical Machines Part I: Rating & Performance Ed. 10.2 IEEE 43-2000 Recommended Practice for Testing Insulation Resistance of Rotating Machinery IEEE 95-2002 Guide for Insulation Maintenance of Large AC Rotating Machinery...
Page 31 D30R Users Manual IEEE Customer Service 445 Hoes Lane P.O. Box Piscataway, NJ 08855-1331 Phone: 1-800-678-IEEE Fax: 908-981-9667 Reprints of NEMA standards are available from: National Electrical Manufacturers Association (NEMA) Global Engineering Documents Phone: 1-800-854-7179 International: 303-379-2740 Do Not Touch Test Leads while test is in Progress!
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Page 33: Chapter 3: Coil Resistance Testing
D30R Users Manual 3: C HAPTER ESISTANCE ESTING Inside: • Principles of Coil Resistance Testing • Resistance Test Display • Resistance Test Checklist • Auto Ranging Resistance Measurements • Saving & Recalling Measurements • Indications of problems in a motor...
Page 34 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 35: Principles Of Coil Resistance Testing
Therefore, the measured resistance value should be “corrected” to a common temperature, usually 25 C, before comparing two different measurements. MTA for Windows, a data logging application for the D30R, does this correction. See IEEE 118 for more information on correcting resistance measurements to 25...
Page 36: Resistance Test Checklist
D30R Users Manual Resistance Test Checklist 1. Disconnect the high voltage test leads and move them aside. Baker tester resistance test circuitry is protected internally by relays, which ground the resistance test leads when a surge or HiPot test is selected. However, the protection relays are in no way rated for any type of live electrical buss or circuit.
Page 37: Auto Ranging Resistance Measurement Algorithm
(20-50mA) into the coil and measuring the voltage drop across the coil. If the Baker tester does not detect a voltage drop, the current will be increased to approximately 0.2 amps and the voltage drop measured again. If a sufficient voltage is still not developed across the coil, the current will be raised to 2 amps.
Page 38: Indications Of Problems In A Motor
D30R Users Manual 2. Use the UP and DOWN keys to select the appropriate Record to store the test in. 3. Press SELECT. The tester then displays a clear test screen. 4. To Recall the Record, Select RECALL. 5. The Record screen will reappear. Using the UP and DOWN keys, select the appropriate record.
Page 39: Chapter 4: Principles & Theory Of Dc Testing
D30R Users Manual 4: P & T HAPTER RINCIPLES HEORY DC T ESTING Inside….. • Principles of DC Testing • Principles of the Megohm Test Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 40 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 41: Principles Of Dc Testing
To perform any of the DC Tests, the motor’s windings are isolated from ground, the red test leads from the Baker Tester are connected to the motor’s three phase coils and the black test lead is connected to the motor’s steel core/frame. The output voltage on the red test leads is raised to a predetermined test voltage and the leakage current flowing from the motor’s coils, through the ground wall...
Page 42 D30R Users Manual motor’s steel core plus any surface leakage currents. The surface leakage currents flow through moisture or contaminants on the surface of the insulation. To accurately determine the insulation resistance, the surface leakage must be reduced to an inconsequential level.
Page 43 NEMA Class F NEMA Class H The Baker tester will automatically calculate the PI value at the end of a 10- minute test. At the test’s conclusion, the PI value may be stored in one of the 10 memory locations in the Baker tester for later recall.
Page 44 D30R Users Manual IR(3min) IR(30s) There are no accepted minimum or maximum values of the DA test. However, the DA value is considered to be trendable. Any change in the DA value indicates that something is changing in the ground wall insulation system. The stator may be contaminated or wet.
Page 45: Chapter 5: Performing High Voltage Dc Tests
D30R Users Manual 5: P HAPTER ERFORMING DC T OLTAGE ESTS Inside….. • The Test Display • General User Cautions & Notes • Test Precautions • High Voltage DC Test Checklist • DC Testing • Full DC Testing of a Motor •...
Page 46 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 47: The Test Display
D30R Users Manual The Test Display Fig 5-1: Test Display Main Menu for Function buttons and Message area. b. Time duration of DC Tests: Voltage Bar d. Current Bar Results from 30 sec, 1min, 3 min, 10 min, PI, DA Mohm, HiPot, Digital Output;...
Page 48: Test Precautions
Do not connect both the resistance test leads and the high voltage test leads to the motor at the same time. • Please do not hesitate to contact Baker Instrument Company for technical applications assistance at (970) 282-1200, or toll free at (800) 752-8272. Fax your questions, information, printouts, diagrams, or photographs of your tests to (970) 282-1010.
Page 49: High Voltage Dc Test Checklist
“DC HiPot”, is done to prove that insulation has the dielectric strength to withstand typical over voltages that a motor can see while in service due to transients, lightening strikes, loss of a phase, etc. The Baker DR Series digital testers are capable of performing all described tests during the same application of voltage to the motor.
Page 50 3. Move Function Knob to the 100uA/Div position. 4. Press and hold “Test” button. The “Test” button needs to be pressed for the duration of the 10-minute test. Baker has a footswitch that can be used to replace the “Test” button for easier use.
Page 51 D30R Users Manual two values are required for calculation of the DA and PI tests. The tester automatically acquires these values. Fig 5-4: Test Active to 60 seconds 8. Continue to press and hold “Test” button. In the screen’s center, the tester will acquire and display a Leakage Current Reading at 3 minutes.
Page 52 D30R Users Manual 9. After 10 minutes of continual testing, the tester will automatically acquire and display the leakage current. The PI ratio will be automatically calculated and displayed. Fig 5-6: Test Active 10 Minutes 10. Continue to press and hold “Test” button, and turn Function knob to 100uA/div position.
Page 53: Performing Only A Megohm Test
D30R Users Manual Fig 5-7: DC Tests Complete 14. Save test results by pressing the “Store” button and selecting desired record. Performing Only a Megohm Test 1. Connect appropriate high voltage leads to stator windings. 2. Move Test Lead selector switch to “HiPot”...
Page 54: Performing Only Dc Over Voltage Test (Dc Hipot Test)
D30R Users Manual 3. Move Function Knob to 100uA/Div position. 4. Press and hold “Test” button. Ramp test voltage to desired Megohm test voltage and press the “Time=0” button at the top of the screen after reaching required voltage. 5. Adjust “uA/div” knob if required to get the machine in the most accurate current range for observed leakage current.
Page 55: Sample Data Showing Good & Poor Insulation
D30R Users Manual 6. After time has elapsed for the DC Over Voltage Test, usually 60 seconds per IEEE 95, press the “Save Meg” button. Megohm data will be displayed in the middle of the screen between the voltage and current slider bars.
Page 56: Storing The Test Results In Memory
D30R Users Manual Fig 5-13: Sample Data-Good Insulation with high voltage and low leakage current. Fig 5-14: Sample Data - Poor Insulation with low voltage and high leakage current. Storing the Test Results in Memory 1. Press the “STORE” soft key. A list of available Records appears.
Page 57: Using The Foot Switch
To enable hands free operation, a foot switch is available for use with the Baker tester. The foot switch plugs in the front panel as shown and may be used in place of the test button.
Page 58: The Hipot Over Current Trip Indicator
D30R Users Manual The HiPot Over Current Trip Indicator The Digital tester is equipped with an Auto-Ranging HiPot Over-Current safety trip. If the HiPot current levels exceed: • ~900uA in the 100uA/div range, • ~90uA in the 10uA/div range, •...
Page 59: Step Voltage Test
Voltage tests, beginning with measurements made when the winding is new. Use the same voltage increments and time intervals for all Step-Voltage tests of a particular winding. Baker Instrument Company recommends that results are plotted on graph paper in order to make comparisons of different tests.
Page 60 D30R Users Manual 6. Move Function Knob to the 100uA/div setting and increase voltage to 4000 volts. 7. Change uA/div range to best match the observed leakage current. 8. At the end of the next minute (2 min after start of test), note the resistance reading.
Page 61: Chapter 6: Principles And Theory Of Surge Testing
D30R Users Manual 6: P HAPTER RINCIPLES AND HEORY URGE ESTING Inside….. • Principles of Surge Testing • Surge Testing Theory • Determination of a Fault • Motivation for Surge Testing • Contact Bounce • Lightening Strikes • Inverter Transients •...
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Page 63: Principles Of Surge Testing
“surge waveform” in progress. The surge waveform is a representation of the voltage present across the test leads of the Baker tester during a test. The indication of a turn-to-turn fault is a shift to the left, and/or a decrease in amplitude of the surge test waveform as the test voltage is increased.
Page 64 D30R Users Manual is the primary one.) The coil becomes one of two elements in what is known as a tank circuit – a LC-type circuit made up of the coil’s inductance (L) and the surge testers internal capacitance (C).
Page 65: Determination Of A Fault
D30R Users Manual Determination of a Fault If a fault exists in a motor, the wave pattern on the display will collapse in amplitude and a distinct shift to the left will occur, signifying an increase in frequency (a decrease in inductance). When inductance decreases, the frequency of the wave pattern will increase according to the formula above.
Page 66: Contact Bounce
Line surges caused by other motors or transformers tripping in the power system. One of the primary functions of a Baker Tester is to closely simulate the transient voltages seen by the motor without the high energy that accompanies the normally occurring transients. These spikes are a significant aging factor for the end turn insulation of an electric motor.
Page 67: Igbt Switching Technology
These IGBT devices are very fast switching transistors. These are often found in variable speed motor drives and are used in the D30R in much the same manner as in the drives. However, Baker Instrument Company has uniquely configured many IGBT devices in series to form the high voltage switch.
Page 68 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 69: Chapter 7: Performing Surge Tests
D30R Users Manual 7: P HAPTER ERFORMING URGE ESTS Inside….. • Surge Test Display • Surge Test Setup • 480V 3 Phase Motor Check List • Single Coil Surge Test and Setup Do Not Touch Test Leads while test is in Progress!
Page 70 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 71: General User Cautions And Notes
D30R Users Manual Surge Test Display Fig 7-1: Surge Test Display Main Menu b. Digital Peak Voltage Readout Number of surge pulses applied to the test winding d. Example of a surge wave pattern Volts/Div Setting, current Test Name, Seconds/Div setting...
Page 72: Surge Test Setup
• Please do not hesitate to contact Baker Instrument Company for technical applications assistance at (970) 282-1200, or toll free at (800) 752-8272. Fax questions, information, printouts, diagrams, or photographs of tests to (970) 282-1010.
Page 73 D30R Users Manual 1. Connect the motor as shown in one of the figures above. Connect phase 1 to Test Lead 1, phase 2 to Test Lead 2, phase 3 to Test Lead 3, and the motor core to the black ground lead.
Page 74: 480V Three Phase Motor Check List
D30R Users Manual 480V Three Phase Motor Check List Check to ensure there is nothing connected to the coil or winding being tested. This is extremely important when testing installed coils or windings. Test inaccuracies will result and the situation can be hazardous to personnel performing tests.
Page 75 D30R Users Manual test voltage of 4000V, a setting of 500 Volts/Div would result in a wave pattern with 8 divisions amplitude which would go off the screen. 10. Watch the surge waveform display while the voltage is increasing looking for flickering display, a drop in amplitude or a jump of the waveform to the left of the display.
Page 76: Single Coil Surge Test And Set-Up
D30R Users Manual 12. Move the Test Lead Selector Switch to Lead 3. 13. Repeat Steps 5 through 8 for Lead 3 and again save the data in the testers memory as was done in step 12. Note: A good way to check the wave patterns after the test is complete is to display all three wave patterns at once.
Page 77 D30R Users Manual setting of 500 will give a wave pattern with 4 divisions of amplitude that does not go off the screen. For a test voltage of 4000V, a setting of 500 Volts/Div would result in a wave pattern with 8 divisions amplitude which would go off the screen.
Page 78: Example: Comparison To A Master Coil
D30R Users Manual 2. Press the key corresponding to QUICK STORE. The wave pattern is now stored in Record #1, Lead #1 and is immediately recalled on the screen. Store the pattern conventionally if the tests are to be downloaded to a pc for further analysis.
Page 79 D30R Users Manual Occasionally, a manufacturer may want to test against a standard. The selected standard coil is surge tested, results are stored in memory and recalled to the screen. QUICK STORE is useful for this situation. All unknown coils would be tested and compared to the standard coil’s wave pattern.
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Page 81: Chapter 8: Surge Test Applications
D30R Users Manual 8: S HAPTER URGE PLICATIONS Inside….. • Maintenance Testing • Single Phase Motors and Two Terminal Divices • Form Coils • Three Phase Motors • Two or More Single Coils • Wound Rotor Motors • Synchronous Motor/Generator •...
Page 82 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 83: Maintenance Testing
Phase-to-Phase short. Maintenance Testing Baker Instrument Company Surge Testers have become extremely popular for industrial maintenance programs, troubleshooting, and to ensure that replacement motors (spares, reconditioned motors, or rewinds) are thoroughly tested.
Page 84: Application Notes
D30R Users Manual Consider a 460V AC motor. The operating voltage is the root mean square, a kind of average, of the AC power supply. For this motor, multiply 460V by 1.4 to determine the maximum voltage level that the coil undergoes during normal operation.
Page 85: Single Phase Motors And Two Terminal Devices
D30R Users Manual checked by firmly grasping the boot and clip in one hand while pulling on the lead with the other. A broken lead will stretch. A good lead will not stretch. Fig 8-2: Open phase in lead in a wye-connector motor.
Page 86: Form Coils
D30R Users Manual Fig 8-3: Good Coil & Bad Coil If any wave pattern becomes erratic and/or flickers during testing, intermittent shorting or arcing is probably occurring in the windings under the voltage stress. Arcing is often accompanied by audible sounds. It may be desirable to store the wave pattern produced by this arcing for reference if the operator can release the TEST (this freezes the wave pattern.) at the moment when the wave pattern...
Page 87: Three Phase Stators
Digital Tester allow all three phases to be compared without removing and reconnecting the test leads. The operator simply recalls any one of the previously tested leads. Baker Instrument Company recommends the following procedure: 1. Connect the three numbered RED test leads to the three winding legs.
Page 88: Determination Of A Fault
D30R Users Manual 4. Perform the test as described in Three Phase Motor Surge Test and Set-Up. For each test, check the display for a wave pattern. Recall a SUMMARY from the digital tester’s memory for wave patterns for the motor to compare. If three good wave comparisons are seen, there is every indication to believe the motor is good.
Page 89: Determination Of A Fault
D30R Users Manual 2. Connect test lead #2 to the second coil or identical coils and connect test lead #3 to that coil’s other side. 3. Surge test the first coil with the TLS in position #1. Store the results in memory.
Page 90: Wound Rotor Motors
D30R Users Manual pole pieces, one of which is making better magnetic contact with the rotor then the comparing pole. For this reason it is recommended that devices like pole pieces be evaluated individually and Not compared. • Paschen’s Law states that a voltage greater than 334 volts is required to initiate an arc between two conductors in air.
Page 91: Determination Of A Fault
D30R Users Manual 3. Surge test the stator as would be done on a three phase induction motor. See Three Phase Stators or follow the directions in Three Phase Motor Surge Test and Setup. Note: Since the rotor is shorted out there will be no chance for a high induced voltage transformed from the stator to damage the rotor.
Page 92: Synchronous Motor/Generator
D30R Users Manual Synchronous Motor/Generator The synchronous stator is tested as a three phase induction motor. The rotating fields should be tested individually. 1. Before surge testing the stator. Remove the DC Leads to the brush boxes or lift all of the brushes off the slip rings.
Page 93: Chiller Motor Testing
If the impedance of the coils is very low (few turns count, generally form coils with very low resistance) the surge tester stand-alone may not adequately test the coils. A bar-to-bar, low impedance test accessory from Baker Instrument Company will be necessary.
Page 94: Armatures
D30R Users Manual Armatures There are two methods of surge testing armatures: the Bar-to-Bar surge test and the Span surge test. The use of a Footswitch is highly recommended to ease the operation of these tests. Bar-to-Bar Surge Test Bar-to-Bar armature surge testing is the most effective method to test DC armatures and detect winding insulation weaknesses and faults.
Page 95 D30R Users Manual The wave pattern produced in this test represents the voltage oscillation between the tester and the coils for the specific number of commutator bars spanned. For example, any 10 bars spanned in series on the armature should give the same pattern as any other 10 bars spanned.
Page 96: Determination Of A Fault
D30R Users Manual Note: The Zero Start Interlock is disabled only when the Funtion switch is set to AT101 for the AT101D accessory (See Supplement #: Model AT101D) and the Footswitch is depressed. Without the accessory and a footswitch, the Output must be turned back to zero or Min and then brought back up to the peak voltage value noted above in Step 6.
Page 97: Notes And Tips For Span Testing Armatures
D30R Users Manual Fig 8-5: Fault located under the ground brush Fault grounded under the hot brush or outside of the surge test span Notes and Tips for Span Testing Armatures • A test fixture can be used in place of using the motor’s brushes to make contact with the armature.
Page 98: Testing Large Ac Stators/Motors
D30R Users Manual low inductive load may cause difficulty achieving the desired test voltage and a good ringing wave pattern on the screen. • To simulate a fault, use an insulated screwdriver to temporarily short two commutator bars together that are in the “test area”. This shows the response of the wave pattern when a fault exists.
Page 99: Notes And Tips For Large Ac Stator/Motors
D30R Users Manual Fig 8-6: Seconds/Div set too far CW Seconds/Div adjusted CCW To correct for this display condition turn the Seconds/Div control counter- clockwise, slowing the sweep rate. The correct surge wave pattern will always extend below the zero line. Observe the natural ringing to the right of the point where the wave pattern crosses the zero line in a positive (upward) direction.
Page 100: Rotor Loading (Coupling) When Testing Assembled Motors
D30R Users Manual Rotor Loading (Coupling) when Testing Assembled Motors When testing assembled motors, the rotor can influence the shape of the surge wave pattern. These influences are as follows. 1. Loss of wave pattern amplitude: The inductive loading of the rotor causes rapid dampening (little to no cycles of the ringing pattern) of the wave pattern.
Page 101 D30R Users Manual detailed instructions for surge testing and Storage and Print capabilities for discussions of the storage and recall functions. 1. Surge test phase #1 of the motor. Store and recall the wave pattern by using the quick store function.
Page 102: Testing Assembled Motors From The Switchgear
D30R Users Manual Testing Assembled Motors from the Switchgear The Surge and HiPot tests are valid tests when testing from the switchgear at the motor control center. Not only are the windings of the motor tested, but the insulation on the connections and feeder cables phase-to-phase and phase-to- ground are tested.
Page 103: Transformers
The following procedures for single phase and three phase transformers provide the basics necessary to surge test transformers. Please call Baker Instrument Company at 800-752-8272 for further assistance or if difficulties are encountered when testing transformers.
Page 104: Three Phase Transformers
D30R Users Manual Fig 8-9: Single Phase Transformer Connections 3. Surge test the winding following the procedures outline for Single Phase Motors and Two Terminal Devices. The discussion of determining a fault applies. NOTE: Secondary winding insulation problems are reflected into the primary winding, and will be observed on the display.
Page 105: Determination Of A Fault
D30R Users Manual 3. Follow one of the charts below for connections for wye-wye or delta- wye transformers. The transformer windings should be surge tested for all the configurations shown. 4. Test procedures follow identically as for Single Phase transformer...
Page 106 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 107: Chapter 9 Documenting Tests
D30R Users Manual HAPTER OCUMENTING ESTS Inside…… • Test Data Storage • Recalling Test Data • Printing Reports • Compatible Printers Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 108 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 109: Store
10 motors or windings. This applies to Surge and DC HiPot testing. The data can also be uploaded to a computer using Baker Instrument Company’s MTA for Windows software for further analysis.
Page 110: Store Record Submenu Options
D30R Users Manual Store Record Submenu Options QWK STR DOWN SELECT QWK STR UP moves DOWN moves Press SELECT to represents the cursor the cursor down choose the Record QUICK STORE. up the the Record list. that the cursor is Record list.
Page 111: Store Hipot And Pi Data
D30R Users Manual Fig 9-1: Store Resistance Data Store HiPot and PI Data If the tester is currently in the HiPot mode, the next display will allow the user to choose whether to store HiPot or Polarization Index data into memory.
Page 112: Store Surge Data
D30R Users Manual Store Surge Data If the tester is currently in the Surge mode, the display will allow the user to choose the Lead location in memory for Surge tests. Three Lead locations are available for each Record. Fig 9-3: Store Surge Data...
Page 113: Recall
D30R Users Manual Recall RECALL is used to retrieve measurements from internal memory to the display. Choosing RECALL reveals a list of memory locations available for resistance, HiPot and surge tests. Ten available Record memory locations are then listed on the display.
Page 114: Recall Hipot Data
D30R Users Manual Fig 9-4: Recall Resistance Data Recall HiPot Data If the tester is currently in HiPot mode, the tester will display the recorded HiPot and Polarization Index data for the selected Record. Fig 9-5: Recall HiPot Data Do Not Touch Test Leads while test is in Progress!
Page 115: Recall Surge Data
D30R Users Manual Recall Surge Data If the tester is currently in Surge mode, the next display allows the user to choose the Lead location from which to recall a wave pattern. Three Lead locations are available for each Record.
Page 116: Print
D30R Users Manual Motor Surge Test and Set-up, step 9 for procedures to compare two surge wave patterns simultaneously. Print Print will print the record currently on the display. Clear Clear will remove or blank out the wave pattern and message area of the display.
Page 117: Compatible Printer Information
D30R Users Manual Compatible Printer Information The HP printer support includes those HP printers that use the Hewlett-Packard PCL 3 printer language/command set. A non-inclusive list of compatible printers follows: • 500C • 550C • 600C • 610C • 612C •...
Page 118 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 119: Appendix A: Typical Winding Faults
D30R Users Manual A: T PPENDIX YPICAL INDING AULTS Inside…. • Typical Winding Faults Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 120 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 121 D30R Users Manual For initial determination of winding faults, refer to the following figures. These wave patterns are typically seen for three phase, wye-connected, lap-wound induction stators. They provide a reference for associating a characteristic wave pattern with a fault type.
Page 122 D30R Users Manual Note: If all three wave pattern wave comparisons surge testing show considerable separation when testing three phase windings, the motor has a Phase-to-Phase short. Because two phases are faulty, a good wave pattern will not be achieved in any position of the TLS.
Page 123: Appendix B: Troubleshooting
D30R Users Manual B: T PPENDIX ROUBLESHOOTING Inside… • Self Help & Diagnosis • Applications – What to do First • Common Application Problems • Service: What to do first • HiPot Display Checks • HiPot Over Current Trip Check •...
Page 124 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 125: Self Help And Diagnostics
Self Help and Diagnostics Problems in testing often crop up. If a problem is being experienced and the problem might be with the Baker Instrument Company Digital Tester, please take the following steps before calling or returning the unit. By performing these procedures and having the requested information available, Baker Instrument Company’s Service or Applications Departments will be able...
Page 126: Applications: What To Do First
Review the section below on Common Application Problems. Please have Basic Information about the tester and specific information about the motor being tested should be available when calling or faxing to assist Baker Instrument Company personnel in determining a solution to the problem.
Page 127 J8 jumper, clip it out with a small diagonal cuter, replace the cards in the order taken out. 5. How to test using the Baker Instrument with a generator to supply AC power at a remote site.
Page 128 Quite high levels of RFI/EMI may be generated when the PP30D is doing a surge test. Print the results after testing is done, it will prolong the service life of the Baker Instrument and any peripheral devices such as printers or laptop personal computers.
Page 129: Service: What To Do First
D30R Users Manual nose pliers. Baker specifies the following fuse rating: 5x20mm 250V 2.5A Slow-Blow. 12. The screen shows a wavy appearance when the unit is at or near maximum output surge test voltage. The AC power source needs to supply at least 200 watts with minimal sag. If the AC supply is extremely weak, the CRT may show some wavy appearing lines.
Page 130: Hipot Display Checks
Note: It is not necessary to run the output control at a high level to determine if the analyzer is working properly. If the display still shows NO voltage bar call Baker Instrument Company Service Department. Use a meter to confirm the insulation resistance of the device being tested.
Page 131: Open Ground Check
For number 5, or any of the conditions noted above, use a grounding strap to a good earth ground. In the case of number 5, call Baker Instrument Company Service for assistance. There is an override available but precautions should be taken.
Page 132: Precautions For Proper Operation
Warranty Return Please review the Warranty Notes and Shipment sections at the beginning of this manual before sending the tester to Baker Instrument Company for Warranty repair. The Warranty Return Form on the following page MUST BE FILLED OUT and RETURNED with the tester to obtain warranty service.
Page 133 Please give as much information as possible (what is not working, when it happened, what was being tested, any unusual noises, etc.) even if you already talked to someone at Baker Instrument Company by phone. Use the back of this form if necessary.
Page 134 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 135: Procedure
• Testing Accuracy – HiPot Measurements • Voltage Measurement Accuracy – Surge (D12R) • Voltage Measurement Accuracy – Surge (D6R/D3R) • Quality Control/Calibration Procedure D30R Document Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 136 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 137: Technical Specifications
D30R Users Manual Technical Specifications Model D3R Output Voltage 0-30000 Volts Surge Test Max Output 1800-2000 amps Current Pulse Energy 45 joules Discharge .1 micro-farad Capacitance Sweep Range 2-2000µ seconds Volts/Division 1250/2500/5000/7500 Repetition Rate 5 Hz Voltage Measurement & +/- 12%...
Page 138: Accuracy Of Measurements - Coil Resistance Test
D30R Users Manual Accuracy of Measurements - Coil Resistance Test Approximate Range Resolution Full Scale Accuracy Resistance +/- 5% 140Ω - 20Ω 1Ω +/- 5% 20Ω - 2Ω 100mΩ +/- 5% 2Ω - .2Ω 2 mΩ +/- 5% .2Ω - .020Ω...
Page 139: Index
D30R Users Manual NDEX Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 140 D30R Users Manual Do Not Touch Test Leads while test is in Progress! 71-023 Rev C 5/8/2007...
Page 141 D30R Users Manual Applicable Standards · 25, 31 High Voltage DC Tests · 43, 47, 51 HiPot · 25, 27, 29, 30, 38, 43, 45, 46, 50, 59, 60, 61, 75, 78, 99, coil resistance · 27, 37 104, 116 Contact Bounce ·...
Page 142 D30R Users Manual ON/OFF · 20 Temperature · 60 OPEN GROUND WARNING TEST · 20 LIGHT · 21 TEST LEADS · 23 OUTPUT CONTROL · 23 Three Phase Selector Switch · 23 THREE PHASE SELECTOR SWITCH · 24 Training · 11, 15 PI test ·...

Baker D30R User's Manual & Operating Instructions

Preface

Chapter 2: Instrument Overview

Chapter 3: Coil Resistance Testing

Chapter 4: Principles & Theory of DC Testing

Chapter 5: Performing High Voltage DC Tests

Chapter 6: Principles and Theory of Surge Testing

Chapter 7: Performing Surge Tests

Chapter 8: Surge Test Applications

Chapter 9 Documenting Tests

Appendix A: Typical Winding Faults

Appendix B: Troubleshooting

Appendix C: Technical Specifications and Calibration

Procedure

Index

Quick Links

Need help?

Questions and answers

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Summary of Contents for Baker D30R

Table of Contents