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Baker AWAIV-6 User Manual

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User's Manual

Advanced Winding AWA

AWAIV-6, AWAIV-12
Baker Instrument Company, an SKF Group
Company,
4812 McMurry Ave. Suite 100
Fort Collins, CO 80525
(970) 282-1200
(970) 282-1010 (FAX)
800-752-8272 (USA Only)
Note: This equipment has been tested and found to
comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC rules. These limits are
designed to provide reasonable protection against
harmful interference with the equipment is operated in
its installation. This equipment generates uses and can
radiate radio frequency energy and, if not installed and
used in accordance with the product manual, may
cause harmful interference to radio communications. If
this equipment does cause harmful interference, the
user will be required to correct the interference.
Due to the phenomena being observed and the
material properties being measured, this equipment
does radiate radio frequency energy while in the active
test mode. Care should be taken to insure this radio
frequency energy causes no harm to individuals or
other nearby equipment.
Information furnished in this manual by Baker
Instrument Company, an SKF Group Company, is
believed to be accurate and reliable. However, Baker
Instrument Company, an SKF Group Company,
assumes no responsibility for the use of such
information or for any infringements of patents or
other rights of third parties that may result from its
use. No license is granted by implication or otherwise
under any patent rights of Baker Instrument Company,
an SKF Group Company.
Caution: Do not touch test leads while testing is in progress!
Warning:
Baker Instrument Company, an SKF Group Company,
assumes no liability for damages consequent to the use
of this product. No part of this document may be
reproduced in part or in full by any means such as
photocopying, photographs, electronic recording,
videotaping, facsimile, etc., without written permission
from Baker Instrument Company, an SKF Group
Company, Fort Collins, Colorado.
5/21/2008 | 71-015-H EN
AWAIV-6 AWAIV-12
1

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  • Page 1: Advanced Winding Awa

    Information furnished in this manual by Baker Instrument Company, an SKF Group Company, is believed to be accurate and reliable. However, Baker Instrument Company, an SKF Group Company, assumes no responsibility for the use of such information or for any infringements of patents or other rights of third parties that may result from its use.

  • Page 2: Note On Software

    5/21/2008 | 71-015-H EN AWAIV-6 AWAIV-12 Note on Software Use the test equipment version on only the Baker While the AWA is a Microsoft Windows® based test equipment provided; instrument, it is not a computer, which any software Use the desktop version on only a single, available in the market should be installed.

  • Page 3: Limited Warranty

    (including contractual remedies) or In no case shall Baker Instrument Company, an SKF remedies under federal laws or both. The User Group Company, or its agents be liable for any loss of...

  • Page 4: Hardware Warranty Information

    Before inserting any disks into the disk drive or shock absorbing packing material. If the AWA fails, connecting the AWA to a computer network, scan all whether it is under warranty or not, call the Baker disks for viruses. Instrument Company, an SKF Group Company, service department before returning the unit for repair.

  • Page 5: Table Of Contents

    The Error Area Ratio ........28 Accessory interconnection and use ....12 Intermittent operation limits......12 Chapter 3 Instrument overview & Setup ..31 Safety symbols & precautions....... 12 AWAIV-6 & AWAIV-12 (AWA) .....33 STARTUP Symbols on equipment........12 Printer configuration........33 Ground the product ........
  • Page 6 5/21/2008 | 71-015-H EN AWAIV-6 AWAIV-12 The Explore tab..........40 Set-up Test Parameters for Reference The Motor ID tab ........... 41 Waveform ............58 Route tab............41 Testing reference motor........ 58 Adding a route..........41 Testing a production motor using comparison Renaming a Route .........
  • Page 7 5/21/2008 | 71-015-H EN AWAIV-6 AWAIV-12 .............. 89 Testing assembled motors from the VERVIEW ........89 switchgear.............105 ETERMINATION OF A FAULT Good, stable trace.......... 89 Transformers..........106 Single phase transformers.......106 Arcing turn-to-turn short ......89 Three phase transformers .......107 Open circuit ............ 89 Determination of a fault ........107...
  • Page 8 Selecting items ..........131 Shading............131 Buttons ............131 Text fields ............. 131 Scroll bars and Windows® icons ....131 Baker admin or user shell......131 ........132 OFTWARE INSTALLATION Desktop install..........132 Appendix C Technical specifications ....133 CCURACY OF MEASUREMENTS ESISTANCE ..............

  • Page 9: Preface

    5/21/2008 | 71-015-H EN AWAIV-6 AWAIV-12 Preface Inside this chapter − CE declaration of conformity − Intended use of instrument − Technical assistance/Authorized service centers − Positioning of instrument − Intermittent operation limits − Safety symbols & precautions − Symbols on equipment −...
  • Page 10 5/21/2008 | 71-015-H EN AWAIV-6 AWAIV-12 Caution: Do not touch test leads while testing is in progress!

  • Page 11: Declaration Of Conformity

    Declaration of Conformity EN 61000-4-5 EN 61000-4-6 Manufacturer’s Name & Address: EN 61000-4-11 Baker Electrical Instrument Company, an SKF Group Company, I, the undersigned, hereby declare that the equipment 4812 McMurry Ave specified above conforms to the above Directives and Fort Collins, CO 80525 Standards.

  • Page 12: Intended Use Of Instrument

    Note: Do not position equipment in such a way that it is difficult to operate the disconnecting device(s). Accessory interconnection and use The AWAIV-6 and AWAIV-12 are equipped with a footswitch. Please see details about the footswitch in Do NOT touch the test leads, winding or later chapters in this manual.

  • Page 13: Ground The Product

    The unit is for indoor use. If used outdoors, the unit must be protected from rain, snow and other The AWAIV-6, or AWAIV-12 should be kept clean and contaminants. in a dry environment. To clean the unit, wipe with a The unit has been tested for use up to 2000m.

  • Page 14: Repair Parts

    Unpacking the unit Carefully remove the following items from the shipping boxes. − AWAIV-6, or AWAIV-12 − Power Cord − Operator’s Manual Caution: Do not touch test leads while testing is in progress!

  • Page 15: Chapter 1: Test Sequence, Voltages & Applicable Standards

    5/21/2008 | 71-015-H EN AWAIV-6 AWAIV-12 Chapter 1: Test sequence, voltages & applicable standards Inside this chapter − Recommended test sequence − Coil Resistance − Meg-Ohm test − DC HiPot − Step Voltage − Surge − Recommended test voltages −...
  • Page 16 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 17: Recommended Testing Sequence

    Slot liner insulation or enamel wire In order to test motors adequately and to have insulation may be burned or damaged, effective predictive maintenance programs, Baker The motor might be full of dirt, carbon dust, Instrument Company, an SKF Group Company, water or other contaminates, suggests using a specific test sequence.

  • Page 18: Surge Test

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 applied to all three phases of the winding, raised slowly control on the work performed. For motors above to a preprogrammed voltage step level, and held for a 460V, the test voltage would be: predetermined time-period.
  • Page 19 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 St. Louis, MO 63132 Phone: 314-993-2220 FAX: 314-993-1269 Reprints of IEC standards are available from: International Electrotechnical Commission (IEC) www.IEC.ch Reprints of IEEE standards are available from: IEEE Customer Service 445 Hoes Lane P.O. Box Piscataway, NJ 08855-1331...
  • Page 20 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 21: Chapter 2 Principles Of Offline Tests

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Chapter 2 Principles of Offline Tests Inside this chapter − Temperature compensation − Principles of the Resistance test − Principles of the Meg-Ohm test − Principles of the Polarization Index (PI) test − Principles of the Dielectric Absorption (DA) test −...
  • Page 22 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 23: Temperature Compensation

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 This chapter briefly explains the fundamentals of the motor problems. Motors operated in conditions that tests the AWA performs. They are treated in the same allow corrosion, contamination, or other physical sequence that the AWA performs them during an...

  • Page 24: Awaiv-12 Resistance Test

    The AWAIV-6 uses a single set of test leads for both the resistance measurements and other high voltage tests. Since the output voltage of the AWAIV-6 is a low 6kV, a more practical lead switching arrangement is possible, which allows all tests to be performed through the single set of test leads.

  • Page 25: Principles Of The Meg-Ohm Test

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 PI results become confusing when attempting to attribute variations in the PI value to the polarizability Principles of the Meg-Ohm test of the insulator or other affects such as humidity or The Meg-Ohm test consists of applying a DC voltage to moisture, surface leakage or instrument error.

  • Page 26: Principles Of The Dc High-Potential (Hipot) Test

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 resistance rarely behaves in this manner. Instead, the The motivation for doing a DA test is to reduce the current in a typical resistor will increase test time from 10 minutes to 3 minutes. To date there proportionately with voltage until the voltage is within are no standardized accepted values for the DA test;...

  • Page 27: Principles Of The Surge Test

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Table 2-1 IEEE test voltages Note: IEEE references NEMA MG 1-2006 Part 12, Page 2 and states that in no case should the test voltage be less than 1500 volts. The Step Voltage test is necessary to insure the...

  • Page 28: The Error Area Ratio

    The surge waveform is the voltage present across the test leads of the Baker during the test. The The Error Area Ratio indication of a turn-to-turn fault is a shift to the left,...
  • Page 29 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 from a single lead or phase to itself. This application of the EAR is called the pulse-to-pulse EAR (abbreviated ppEAR). To explain the ppEAR, recall that the arcing turn- to-turn short is identified by a shift to the left of the surge waveform as the test voltage is slowly increased.
  • Page 30 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 31: Chapter 3 Instrument Overview & Setup

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Chapter 3 Instrument overview & Setup Inside this chapter − AWA startup − Printer Configuration Caution: Do not touch test leads while testing is in progress!
  • Page 32 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 33: Awaiv-6 & Awaiv-12 (Awa) Startup

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 connected to the printer and the proper printer driver AWAIV-6 & AWAIV-12 (AWA) startup must be selected. The AWA requires adequate ventilation. Place the unit where air can circulate freely around it and avoid Provided memory key locations in direct sun or near heat sources.
  • Page 34 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 35: Chapter 4

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Chapter 4 Software navigation Inside this chapter − Database management Starting the software Creating a new database Opening an existing database Multiple databases First time version 4 software is used − The motor tree...
  • Page 36 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 37: Database Management

    Consequences of not organizing data or updated. Since the Baker tester can be configured to store every To view test results for a given motor or to test it ever performs, it is recommended to establish a...

  • Page 38: Starting The Software

    Save button. A database will be created on the Windows® desktop. The AWA software will and opened that has one default motor and the Baker start and present a window with two options: to create default Test ID’s.

  • Page 39: Multiple Databases

    This information will be used to track each data record to identify which AWA acquired the given record. Motor tree It is usually entered at Baker, before the AWA is shipped. It may be changed though calibration, which After selecting or creating a database, the above can be invoked from the Tests Tab, Enable window appears.

  • Page 40: Motor Id Field

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 fields may be renamed to Plant and Unit. These Motor ID field location fields along with the Motor ID are entered as The records that are stored by the AWA are linked to part of the nameplate record and are used to make up each other hierarchically.

  • Page 41: The Motor Id Tab

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 becomes the current motor. Expand a motor location The Route tab allows the user to construct individual by clicking on the plus sign or contract a location by lists of Motor ID’s for routing purposes. As seen in the clicking on the minus sign.

  • Page 42: Renaming A Route

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 When finished editing a route click on the Renaming a Route Update List button to save changes. Select the Route in the Route ID’s combo box to rename. Click on the Rename button. The Route Id will be highlighted. Edit the Id to the desired change, and click the Update button.

  • Page 43: Chapter 5 Viewing Data - The Data Tab

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Chapter 5 Viewing data – the data tab Inside this chapter − Nameplate view Adding a motor Updating an existing motor − Application view − Results summary grid view − Surge view − PI view −...
  • Page 44 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 45: Viewing Data

    Explore tab to help locate a motor. All other fields in the Nameplate view are optional. Enter any other information needed for tracking. Note: Many of Baker’s industrial customers have found When finished, click on the Save button. When having all nameplate fields filled in greatly helps their...

  • Page 46: Updating An Existing Motor's Nameplate Information

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 appropriate voltage class is a required field to The Application view provides a place to enter data enter. about a particular test. Such information as who did Enter the Test ID to be used when testing the the test, who the test was done for, which MCC the test new motor.

  • Page 47: Data Tab, Surge Views

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 be gray. Use the scroll bars to the right and bottom to scroll through the results for each test category. The side-by-side nature of this view allows comparisons to be made easily by allowing all test results for a motor to be seen.

  • Page 48: Data Tab, Step/Ramp-Voltage Test View

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Data tab, Step/Ramp-Voltage test view Pressing the Step/Ramp-Voltage tab displays the Step Voltage test data in both graphical and tabular form. The graph defaults to plotting current vs. voltage. The red triangle indicates the current at the end of the step.

  • Page 49: Chapter 6 Setting Up - Tests Tab

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Chapter 6 Setting up – Tests tab Inside this chapter − Temperature/Resistance test screen Manually entered Resistance measurements Wye wound Resistance measurements Delta wound Resistance measurements Coil Resistances − Meg-Ohm/PI/HiPot test screen − Step Voltage test screen −...
  • Page 50 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 51: Tests Tab

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 To edit Test ID’s click on the Edit Test ID check box. Tests tab The user will be prompted for a password. If this is the Pressing the Tests tab displays the screen in Fig 6-1.
  • Page 52 The resistance values may be automatically IEEE 118 recommends 25°C. The constant used to acquired by the Baker tester or acquired by some other convert resistances at one temperature to another is means and manually entered into the AWA software.

  • Page 53: Manually Entered Resistance Measurements

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 checking the Target Corrected Resistance check box different: a measurement made with a bridge will be and entering appropriate resistances. between one lead and another lead with the third lead allowed to float. Due to this difference, the winding configuration becomes even more important.

  • Page 54: Wye Wound Resistance Measurement

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Manually entered data should be of the line-to-line corrected and displayed in the Temp Corrected type of measurement. To enable the manual data column. The coil resistances will also be calculated for entry, press the Manual Entry radio button as shown.

  • Page 55: Ramp Voltage Test

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 minimum PI values are all entered. The PI has two The Ramp Voltage test is used mostly for generators. It extra options: 1) default to the Dielectric Absorption if gives information on the contamination level with the the IR=5000MÙ...

  • Page 56: Surge Test Screen

    Voltage, Step Voltage, and the number of Surge motor with a rotor installed. If it is absolutely necessary Pulses are entered. Baker recommends the Surge to use the L-L EAR with the rotor installed, increase Voltage to be 2V+1000. The Step Voltage controls the tolerance to avoid nuisance trips.
  • Page 57 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 EAR tolerance with installed rotors makes the use of this feature a poor detector of a turn-to-turn insulation problem. The P-P EAR (%) sets the maximum Pulse-to- Pulse Error Area Ratio that will be allowed for the test.

  • Page 58: Set-Up Test Parameters For Reference Waveform

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Multiple tests can be run in order to obtain the Set-up Test Parameters for Reference necessary standard. In automatic mode, test results Waveform are always saved. Reference waveforms will only be part of the Test ID when yes is pressed on the Use as Reference dialog.

  • Page 59: Viewing Surge Results

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 In order to begin testing, press done to return to the Tests screen. Press the Run Auto Test button to begin the test. If the motors have passed all other tests and there is a reference waveform, the AWA application will calculate the Error Area Ratio (EAR) at the end of the surge test.
  • Page 60 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 61: Chapter 7 The Trending Tab

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Chapter 7 The Trending tab Inside this chapter − Max Delta R% − Resistance − Insulation Resistance/Meg-Ohm − − HiPot − Relative humidity − Special features for trending Caution: Do not touch test leads while testing is in progress!
  • Page 62 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 63: The Trending Tab

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 The trending tab Opening the Trending tab brings up a graph that charts acquired data. Trending information such as Max Delta R%, Balance Resistance, L-L Resistance, Coil Resistance, Meg-Ohm (correct or not corrected), PI...

  • Page 64: Hipot

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Pressing the PI button displays the graph trending the Relative humidity PI ratio versus time, and has similar features to the Checking Relative Humidity (RH%) will cause the tool other trending graphs. tips to display the RH% entered at test time. Hover...
  • Page 65 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 often, this feature will be used to exclude a test that contains known bad data that for example, might be acquired in a test that was aborted. To select or deselect dates, use the same type of selection techniques used to select files in Windows Explorer.
  • Page 66 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 67: Chapter 8 Performing An Example Test

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Chapter 8 Performing an example test Inside this chapter − Creating a motor ID − Creating a test ID − Configure Temperature/Resistance − Configure Meg-Ohm/PI/HiPot tests − Configure Surge tests − Generic test ID’s versus specific test ID’s −...
  • Page 68 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 69: Creating A Motor Id

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 The following chapter will go through an example setup just as an operator would if a motor was to be tested for the first time. The first thing to do is create a Motor ID that uniquely identifies the motor –...

  • Page 70: Creating A Test Id

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 password will need to be set. To do this click on the Change Password button and entering a password then click on Set Password.) Click OK, once the application has accepted the password, the Update, Add, and Delete buttons will appear and the voltage class dropdown list will be enabled.

  • Page 71: Configure Temperature/Resistance

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Turn on all required tests by clicking the left most column of ON/OFF buttons. When on, the button will turn green. Proceed to the next section. Leave the Res Leads check box unchecked. The...

  • Page 72: Configure Meg-Ohm/Pi/Hipot Tests

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 25V/step is a typical ramp rate. If the test Configure Meg-Ohm/PI/HiPot tests should run faster, increase this number to To configure the Meg-Ohm/PI/HiPot tests, press 50V or 100V. one of the three buttons to the right of the Meg-...

  • Page 73: Generic Test Id's Versus Specific Test Id's

    Test ID to a High Voltage leads. If the Res Leads is checked, specific motor. Baker has already provided several Test the displayed dialog will request that the Low ID’s based on machine voltage in the database. These Voltage Leads be attached.
  • Page 74 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 to be entered from a third party temperature minutes (180 seconds). At end of the PI test, device. Enter the temperature reading, click if no failures occur the PI/DA dialog will close. − the Accept button to acknowledge the HiPot –...

  • Page 75: Reviewing Test Results/Data

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 The surge test data can be reviewed by pressing the Surge tab. Reviewing test results/data After the test results have been saved to the database, they can be reviewed using the Data tab on the right hand pane of the AWA main window.
  • Page 76 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 down the Ctrl key and pressing the P key, or pressing printer. In Fig 8-18, the Results Summary with Surge the printer icon on the upper left of the main screen. Summary has been selected.
  • Page 77 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 application to look for all test results that took place on other applications can read and display RTF files. The 3/29/2007. Next filter selected is the Pass/Fail. Select RTF report will look substantially the same as the MS the FAIL radio button.
  • Page 78 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 79: Chapter 9 Data Transfer / Database Maintenance

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Chapter 9 Data Transfer / database maintenance Inside this chapter • Data transfer Transferring motor & test results data Transferring test ID’s Transferring nameplate data • Archiving a database • Restoring a database •...
  • Page 80 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 81: Data Transfer

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Data Transfer The Data Transfer tool offers a way to transfer motor and test information from one database (source) to a second database (destination). The transferred information is not deleted from the source database, but only copied to the destination database.

  • Page 82: Transferring Test Id's

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 application is ready for motors to be selected from the The Data Transfer creates a log during the source database to be added to the Transfer List. The transfer process. Information logged is Transfer List is the list of motors that will be source/destination database names, Motors ID’s added,...

  • Page 83: Archiving A Database

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 transfer will continue. As in the motor and test result Note: If the default is the floppy drive or CD-Rom record transfer, the application writes to the Transfer drives make sure there is a diskette/CD in the drive Log as to what action has been taken.

  • Page 84: Converting An Older Database

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 screen. Choose File – Open menu item to open the newly restored database. Converting an older database Version 4 of the AWA software uses a different database structure than prior versions. The test results...

  • Page 85: Converting The Data

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 folder the AWA Data folder can be deleted. As database name filled in: the new name is the old one always, it is advisable to keep an archived copy. with a _Rev4 appended to it, see Fig 9-12. The database name can be changed to whatever is desired;...
  • Page 86 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 87: Chapter 10 Typical Winding Faults

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Chapter 10 Typical winding faults Inside this chapter − Determination of a fault − Application notes − Factors affecting Surge tester output Caution: Do not touch test leads while testing is in progress!
  • Page 88 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 89: Overview

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 patterns seen for three-phase, lap wound induction Overview stators. They provide a reference for identifying a This chapter is designed to assist with interpreting test characteristic wave pattern with a type of fault. results. Through it is not a substitute for experience...

  • Page 90: Hard Sort To Ground

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Application Notes − Knowledge of all types of wave patterns is not necessary when maintenance testing. It is more important to look for a stable, uniform waveform up to the specified test voltage. −...

  • Page 91: Factors Affecting Tester Output

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Rotor loading can be understood when the rotor is impedance devices or devices which exceed the AWA’s considered a secondary of a transformer. When one capability. phase being surged has a different number of rotor For example, the horsepower of a motor may be bars under it’s stator windings than the other phase...
  • Page 92 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Factor Effect Motor larger than Capacitance and inductance of motor windings can load the recommended AWA output down. The voltage output is reduced below max size to test maximum output, which can damage the AWA if the test is applied for an extended period.

  • Page 93: Software Fault Messages

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Software fault messages Status Failure Type Why Failed Message PASS No failure was detected according to the Test Model given. FAIL USER ABORT USER ABORT. An User abort has been detected. FAIL EMERGENCY EMERGENCY SHUTOFF. Emergency Shutoff has been detected...

  • Page 94: Dc Tests Failure Types

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 DC tests failure types FAIL OVER VOLTAGE OVER VOLTAGE. Over Voltage Condition has been detected FAIL OPEN GROUND An open ground has been detected. Check power cord outlet ground for continuity FAIL MIN MEG-OHM Test Result.

  • Page 95: Chapter 11 Applying The Awa

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Chapter 11 Applying the AWA Inside this chapter − Predictive maintenance − Quality control − Motor troubleshooting − Surge reference waveform − Maintenance testing − Single phase motors & two terminal devices − Form coils −...
  • Page 96 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 97: Awa Applications

    The motor is likely Maintenance testing to pass Resistance tests, fail Meg-Ohm tests, fail HiPot Baker Instrument Company, SKF Group Company tests, and pass Surge tests. After the failed Meg-Ohm testers have become extremely popular for industrial...
  • Page 98 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 maintenance programs, troubleshooting, and to ensure service for the motor before a hard short and rapid that replacement motors (spares, reconditioned failure occurs. motors, or rewinds) are thoroughly tested. The Consider a 460V AC motor. The operating voltage...

  • Page 99: Single Phase Motors And Two Terminal Devices

    Refer to the previous section on Single phase and two reconnecting the test leads. Baker Instrument terminal devices to determine if a fault is present. Company, an SKF Group Company, recommends the...

  • Page 100: Two Or More Single Coils

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 good wave comparisons are seen, there is every Determination of a fault indication to believe the motor is good. If anything If any wave pattern becomes erratic and/or flickers other than a good pattern is seen, there is a possible during testing, intermittent shorting or arcing is fault.

  • Page 101: Wound Rotor Motors

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 differences in turns count, which causes a slight, Note: Check the motor nameplate for rotor steady separation. The operator should investigate voltage to calculate the rotor test voltage level. Rotor whether this condition is acceptable or not.

  • Page 102: Chiller Motor Testing

    Two or More Single coils. A bar-to-bar, low impedance test accessory from Coils. Baker Instrument Company, an SKF Group Company, may be necessary. Determination of a fault DC motor/generators Two types of faults may exist in synchronous motors and generators.
  • Page 103 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 for the specific number of commutator bars spanned. returns to the reference wave pattern and remains For example, any 10 bars spanned in series on the stable when the brushes are again centered on top of armature should give the same pattern as any other the bars.

  • Page 104: Testing Large Ac Stators/Motors

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 volt applied to the span will result in 200 volts The screens below show wave pattern between bars. comparisons for a typical 4160V stator. Distortion is − caused by the non-symmetrical, distributed capacitance Consider, however, that a ten bar span at 335 in the input portion of the winding.

  • Page 105: Testing Assembled Motors From The Switchgear

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 bars under its stator windings than the other phase Repeat step for phase #3. All three being surged and compared, there is a different waveforms will be displayed on the screen. transformer action existing for each phase. The wave Differences will be visible.

  • Page 106: Transformers

    If power factor capacitors are phase transformers provide the basics necessary to present, no waveform will be observed when the surge test transformers. Please call Baker Instrument voltage is raised. This will also happen if the motor Company, an SKF Group Company, at 800-752-8272 was not connected to the cable.

  • Page 107: Three Phase Transformers

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Surge test the winding following the procedures Determination of a fault outline for Single Phase Motors and Two To determine a fault when surge testing a transformer Terminal Devices. The discussion of determining winding, follow the procedure that of the two terminal a fault applies.
  • Page 108 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 109: Supplement 1 Power Pack Operation

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Supplement 1 Power pack operation Inside this chapter − Emergency shut-off button − Power pack setup − Power pack DC testing (three phase test lead option) − Power pack surge testing (three phase test lead option) −...
  • Page 110 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 111: Emergency Shut-Off Button

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 condition will also affect the Power Pack due to loss The AWA with the 30kV power pack allows the testing of the surge enable signal. of larger, higher voltae machines that are beyond the...

  • Page 112: Power Pack Set-Up

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 position until manually retracted by rotating the E-Stop The AWA leads are not hooked together button clockwise. No printer or CD ROM’s are hooked up to the USB port. Power pack set-up Power pack resistance testing Note: The 30kV power pack must show on its rear The resistance tests are run with the AWA’s test leads.

  • Page 113: Operating Position

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 simultaneously when attempting to perform the test. If The DC Tests configuration window will appear. the tester is not operated in this fashion, the tests will Adjust the voltage required so that HiPot voltage not be performed correctly, and the data recorded will is at least 2000V.

  • Page 114: Power Pack Surge Testing (Three Phase Lead Test Option)

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Start testing by depressing the power pack’s test Power pack Surge testing (three phase lead button (or footswitch) and slowly raise the power test option) pack’s output control. Test results should immediately be visible on the AWA screen. If not, Follow the instructions for setup.

  • Page 115: Power Pack Dc Testing (Single Phase Lead Option)

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 nested failures, the problem was due to ground Power pack DC testing (single phase lead capacitance. This is a problem sometimes option) encountered in the AWA/PP30. It may scale itself Warning: During Testing, do NOT allow the AWA test (surge wave) into the wrong sweep rate.

  • Page 116: Power Pack Surge Testing (Single Phase Test Lead Option)

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Turn the Output Control knob on the Power Pack Power pack Surge testing (single phase test to MIN (full Counterclockwise). lead option) Select one of the HiPot settings on the Power Follow the instructions for setup. On the AWA, Pack Function knob.

  • Page 117: Combining Awa Host And Pp30 Tests

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 will be erroneous if the coil ground is used instead of voltage windings. the frame grounding. On the AWA screen, you may select the surge lead Combining AWA host and PP30 tests and store test results of three phase windings for surge To completely test a large motor, functions from both comparison.

  • Page 118: Running The Test

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 choose a voltage class. For example PP30_4160 and Turn on the Resistance, Meg-Ohm, PI, HiPot and voltage class of 4160 is shown being created. Surge tests. Enter test screen to properly configure each of the tests. The HVDC test setup screen is shown to the right.

  • Page 119: 220/240 Vac Units

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Meg-Ohm and PI test. Once the PI test is finished, AWA will automatically stop the test, disable the PP30’s testing will stop, and the dialog in Fig Sup-7 will pop test leads and discharge the windings.
  • Page 120 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 121: Appendix A - Awa Troubleshooting

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Appendix A - AWA troubleshooting Inside this chapter − Applications: What to do first − Service: What to do first − Precautions for proper operation − Proper storage of leads/unit − Checking test leads for broken sections −...
  • Page 122 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 123: Self Help And Diagnostics

    Problems in testing often crop up. If you are experiencing a problem and believe the problem might Review the section on common application problems. be with the Baker Instrument Company, an SKF Group Please have basic information about the tester and Company, Surge/DC HiPot Tester, please take the specific information about the motor being tested following steps before calling or returning the unit.

  • Page 124: Service: What To Do First

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Separation of compared surge wave patterns is A broken test lead may be the cause. Under seen when surge testing known-good coils, brand heavy use, test leads should be checked weekly to new motors or windings. Often, separation is ensure that there is no breakage.

  • Page 125: Hipot Display Checks

    AWA is working transformer-isolated circuit? properly. If the display still shows no voltage bar call Baker If the answer is yes to any of these questions, the Instrument Company, an SKF Group Company, service unit is probably operational and indicating that there is department.

  • Page 126: Proper Storage Of Leads/Unit

    If the tester continues to ramp up and have to be sent to Baker Instrument Company, an to the test voltage, the black test lead is SKF Group Company, for replacement. Even though broken.

  • Page 127: Third Party Software Warning

    Warranty return Please review the warranty notes and shipment sections at the beginning of this manual before sending your tester to Baker Instrument Company, an SKF Group 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 128: Warranty Return Form

    ______________________________ records prior to sending this to Baker Instrument Company, an SKF Group Company. Ship the Tester to: Baker Instrument Company, an SKF Note: Be sure to follow the guidelines for shipping Group Company,, 4812 McMurry Avenue, Fort Collins, when sending the tester to Baker Instrument CO 80525, Attn: Service Manager Company, an SKF Group Company.

  • Page 129: Appendix B Software Installation/ Maintenance

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Appendix B Software installation/ maintenance Inside this chapter − General Windows® information − Upgrade − Complete rebuild − Desktop installation Caution: Do not touch test leads while testing is in progress!
  • Page 130 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 131: Navigating Through The Software Interface

    Two modes are available – the Baker admin and user shell. There are Shading several ways to enter into these modes. The Baker The shading of the images on the various screens of admin shell can be reached from a desktop shortcut or the programs is significant.

  • Page 132: Software Installation

    Software installation Since there are periodic upgrades and fixes to computer driven products, it makes sense to keep in touch. Contact Baker Instrument Company, an SKF Group Company, by calling 970-282-1200 or 800- 752-8272 (US only) or access the website at www.bakerinst.com.

  • Page 133: Appendix C Technical Specifications

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Appendix C Technical specifications Inside this chapter • AWA IV-6, AWAIV-12, AWAIV-12HO technical specifications Caution: Do not touch test leads while testing is in progress!
  • Page 134 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!
  • Page 135 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Technical specifications Surge Test AWAIV-6 AWAIV-12 AWAIV-12HO Output Voltage 0-6000 Volts 0-12000 Volts 0-12000 Volts Max Output Current 350 amps 400 amps 400+ amps Pulse Energy 0.72 joules 2.88 joules 7.2 joules Storage Capacitance .04μF...

  • Page 136: Accuracy Of Measurements - Coil Resistance Test

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Accuracy of measurements - Coil Resistance test Resistance Balance Test (High Voltage Leads) Range Resolution Full Scale Accuracy *10Ω- 50Ω .2Ω +/- 5% 2Ω - 20Ω .1Ω +/- 5% .030 - 2.0Ω .01Ω +/- 5% **.000 - .4Ω...

  • Page 137: Voltage Measurement Accuracy - Surge

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Voltage Measurement Accuracy - Surge Range Resolution 500V/Div +/- 12% from 500V – 1960 V 1000V/Div +/- 12% from 500V – 3930 V 2000V/Div +/- 12% from 1000V – 7870 V 3000V/Div +/- 12% from 2000V – 11900 V...
  • Page 138 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!

  • Page 139: Index

    5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Index Caution: Do not touch test leads while testing is in progress!
  • Page 140 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Caution: Do not touch test leads while testing is in progress!
  • Page 141 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Accuracy of Measurements · 136 IEC · 18 Analyzer Physical Startup · 33 IEEE · 18 Applicable Standards · 18 Meg-ohm · 17, 135 Buttons · 131 Megohm Test · 15, 17, 21, 25, 97 Database Management ·...
  • Page 142 5/21/2008 | 71-015-H EN AWAIV-12 AWAIV-6 Text Fields · 131 Three Phase Test Lead Option · 112 Tree View · 113, 114, 115, 116, 131 Scroll Bars and Windows Icons · 131 Turn-to-Turn Short · 89 Set-up Test Parameters · 58 Shading ·...

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