Baker Manual # 1

User’s Manual
DC HiPot/Surge Tester (Power Pack)

Model PP24
Baker Instrument Company, an SKF Group Company

4812 McMurry Avenue
Fort Collins, CO 80525
(970) 282-1200
(970) 282-1010 FAX
(800) 752-8272 USA Only
12/7/2009 | 71-026 V2 1
PP24
Warranties and Disclaimers
Warranties; Disclaimers
Limited Warranty as to Baker/SKF Brand Products.
1) Baker/SKF warrants that Baker/SKF brand Products, if any, that are sold under the
Agreement shall be of the kind and quality described in Baker/SKF's acknowledgment of
Buyer's Order, and shall be free of material defects in workmanship and material for a
period from the date of shipment equal to (i) twelve (12) months in the case of new
Products (including factory-installed circuit boards, accessories and options purchased
concurrently with the applicable Product), (ii) six (6) months in the case of used or
refurbished Products, and new circuit boards, accessories and options delivered separately
from the applicable Product, (iii) a period of ninety (90) days from the date of shipment in
the case of used or refurbished circuit boards. If any such Product , accessory or option
is not as warranted, Buyer must notify Baker/SKF thereof in writing within the applicable
warranty period.
2) Baker/SKF's sole obligation, and Buyer's sole remedy, under the foregoing warranty shall
be to provide the parts and labor for the repair or replacement (at Baker/SKF's sole
option) of defective parts, recalibration of any portions of a product that could reasonably
have been affected by the repair, and functional verification to affirm proper operation.
When, subject to the next sentence, the Buyer returns Products, accessories or options
to the Baker/SKF factory for warranty service, Baker/SKF will bear the cost of return
packaging, and shipping , and insurance ,on the return shipment. For Products,
accessories or options that Baker/SKF designates as “on-site service only” due to their
size, the permanence of their installation pr otherwise, travel expenses (including labor
costs for time spent traveling) for warranty services are covered to the location of
original shipment and installation. Products, accessories and options that are capable of
being returned to the factory for service may receive warranty service on site, but all
travel expenses (including labor charges for time spent traveling) shall be the
responsibility of Buyer.
3) For warranty coverage of “on-site service only” items, Buyer must make available to
Baker/SKF a knowledgeable operator to assist with preliminary diagnosis prior to a
service trip being scheduled. Buyer, in connection with a request for on-site service,
must be capable of authorizing charges for the service visit in the event the issues
discovered are not covered by warranty, such as application errors or installation errors.
If Buyer, having elected to perform installations without Baker/SKF’s participation and
having encountered irresolvable problems, shall be charged for an installation if on-site
assistance is necessary, except when defective product is determined to be the cause.
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.
12/7/2009 | 71-026 V2 2
PP24
Table of Contents
Warranties; Disclaimers.............................................................................................................. 2
Limited Warranty as to Baker/SKF Brand Products. .................................................................... 2
1 ........................................................................................................................... 5
Preface.................................................................................................................. 5
IMPORTANT SAFETY INFORMATION .......................................................................................................5
General Safety Precautions ........................................................................................................ 5
Safety term definition ................................................................................................................. 5
Other Important Safety warnings .............................................................................................. 5
Power Source Precautions ......................................................................................................... 6
Ground the product ..................................................................................................................... 6
Operation notes ........................................................................................................................... 6
Symbols on equipment ............................................................................................................... 7
OTHER INFORMATION..........................................................................................................................7
Cleaning & decontamination....................................................................................................... 7
Technical assistance / Authorized Service Centers................................................................... 7
Intermittent operation limits....................................................................................................... 7
Installation requirements............................................................................................................ 7
Unpacking the unit ...................................................................................................................... 7
Power and utility ......................................................................................................................... 8
Environmental.............................................................................................................................. 8
Storage (indoor/outdoor) ............................................................................................................ 8
Shipment ...................................................................................................................................... 8
1 ......................................................................................................................... 11
Getting started ................................................................................................... 11
GENERAL INFORMATION ................................................................................................................... 11
How Does the PP24 Work?......................................................................................................11
Recommended Test Voltages ...................................................................................................12
2 ......................................................................................................................... 13
DC testing/DR unit............................................................................................... 13
Other Important Safety warnings ............................................................................................13
DR DC Tests Operation .............................................................................................................14
Megohm/PI/HiPot testing..........................................................................................................15
3 ......................................................................................................................... 21
Surge testing/DR Unit......................................................................................... 21
SURGE ............................................................................................................................................. 22
Printing a Report .......................................................................................................................26
EAR .............................................................................................................................................26
4 ......................................................................................................................... 29
Testing with a AWA unit ..................................................................................... 29
DC TESTING WITH AN AWA............................................................................................................. 30
Megohm/PI/Hipot Testing .........................................................................................................31
12/7/2009 | 71-026 V2 3
PP24
Table of Contents
5 ......................................................................................................................... 33
Surge Testing/AWA.............................................................................................. 33
SURGE TESTING WITH THE AWA AND PP24................................................................................... 34
Performing Complete Motors Tests with the AWA.................................................................36
Index ................................................................................................................... 37
12/7/2009 | 71-026 V2 4
PP24
1
Preface
Important safety information
General Safety Precautions
Note: The general safety information presented here will be for both operating and service
personnel. Specific warnings and cautions will be found throughout this manual where they
apply.
Note: If the equipment is used in any manner not specified by Baker Instrument Company,
an SKF Group Company, the protection provided by the equipment may be impaired.
Safety term definition

DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING: Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION: Indicates a hazardous situation, which, if not avoided, could result in minor or
moderate injury.
NOTICE: “NOTICE” is the preferred signal word to address practices not related to personal
injury.
Danger
High Voltage
To prevent serious injury or death:
- Do not use in explosive atmospheres.
- Do not contact test leads or device being testing
while test is in progress or during discharge period.
- Do not connect test leads to live circuits.
Read and follow safety precautions and safe operating
practices in operator manual. Do not exceed maximum
operating capabilities of this instrument.
Other Important Safety warnings

Failure to follow these precautions could result in severe electrical shock or death.
1) Never attempt a two-party operation. Always know what test is being performed and
when. FOR EXAMPLE: DO NOT adjust test leads when footswitch is being operated.
Leads will have live voltage and severe electric shock may result.
2) For capacitor-started motors or systems with surge arrestors/power factor capacitors, be

sure to disconnect all capacitors from the test circuit before testing.
12/7/2009 | 71-026 V2 5
PP24
Safety Warnings and Notices
3) Upon completion of a DC High Potential, Megohm, Polarization Index, Dielectric

absorption, before disconnecting the test leads, short the winding, motor, etc., to ground
and allow time for discharge. If this is not done, voltage may still be active on leads and
tested components.
4) Make sure the tester leads are disconnected before the motor is energized or powered
up.
5) Do not remove the product covers or panels or operate the tester without the covers
and panels properly installed. Components on inside of tester carry voltage for operation
and if touched can render a shock.
6) Use appropriate safety equipment required by your organization, including high voltage
globes and eye protection.
7) Repair Parts Warning : Defective, damaged, or broken test leads must be replaced
with factory-authorized parts to ensure safe operation and maintain performance
specifications.
8) Ground the product : This product is grounded through the grounding conductor of the
power cord. To avoid electrical shock, plug the power cord into a properly
wired/grounded receptacle before connecting the product test leads.
a. Danger from loss of ground – Upon loss of the protective ground

connection, all accessible conductive parts, including knobs and controls
that may appear to be insulated, can cause an electric shock!
9) This instrument is NOT waterproof or sealed against water entry.
10) The unit is for indoor use. If used outdoors, the unit must be protected from rain, snow
and other contaminants.
Power Source Precautions

This product is intended to operate from a power source that does not apply more than
nominal 120 volts RMS (ST103/ST106/ST112) or nominal 240 RMS (ST203/ST206/ST212)
between the supply conductor or between either supply conductor and ground. A protective
ground connection by way of the grounding conductor in the power cord is essential for safe
operation.
Ground the product

This product is grounded through the grounding conductor of the power cord. To avoid
electrical shock, plug the power cord into a properly wired receptacle before connecting the
product test leads.
Operation notes
− Irregularities, particularly vertical peaks, may be seen in the first cycle of the wave
pattern. These occur most frequently on large, high voltage motors. Do not interpret
these as faults in the winding. Any winding fault will be seen through the entire wave
pattern.
− Do not change the Test Lead Select, if so equipped, switch setting during a test.
− When increasing the applied voltage, switch to a higher Volts/Div setting so the entire
wave pattern remains visible on the display.
12/7/2009 | 71-026 V2 6
PP24
− Always return the Output Voltage control to Min when a test is complete. Begin each
test at the Min voltage setting. Failure to do so may result in damage to the test winding
and/or the tester.
Symbols on equipment
Protective conductor terminal. Located beside black ground test lead
on front panel of instrument.
Earth (ground) terminal
Frame or chassis terminal. Located on rear panel of instrument by

ground terminal.
Warning about hazardous voltage and risk of severe electrical shock or

death. Located beside each red test lead on front panel of instrument.
Other Information
Cleaning & decontamination

The ST103A, ST106A, or ST112A should be kept clean and in a dry environment. To clean
the unit, power down and unplug the instrument. Wipe with a clean water dampened cloth.
Do not submerge in water or other cleaners or solvents. To clean the screen, take a soft
water dampened cloth and gently wipe the surface.
Technical assistance / Authorized Service Centers

See our website at www.bakerinst.com for technical assistance/authorized service center
information. This information will be marked with an asterisk.
Intermittent operation limits

At this time there are no intermittent operation limits to the use of the AWA unit.
Installation requirements
The unit may be operated
1) Flat on the bottom of the unit,

2) Flat on the back of the unit, or
3) Held at an angle using the rotating handle.
There are no ventilation requirements.

The unit is intended for use in Installation Category II (Portable Equipment) areas and
pollution Degree II Environments where occasional non-conducting condensing pollution can
be encountered.
Unpacking the unit

Carefully remove the following items from the shipping boxes.
ST103A, ST106A or ST112A
Power cord
12/7/2009 | 71-026 V2 7
PP24
Users Manual
Power and utility

Input power must be 110 to 120 VAC at 60 Hz for the ST103/ST106/ST112A (220 to 230
VAC at 50 Hz (single phase source only) for the ST203/ST206/ST212). Please be aware that
fluctuations in input voltage will affect output voltages and calibration.
Environmental
The tester should only be operated in temperatures ranging from 0 to 100 degrees
Fahrenheit (-17.8 to 37.8 degrees Celsius).
As with all insulation dielectric and resistivity measurements, humidity will affect the condition
of the instruments components over time. Relative humidity of the storage environment
should be less than 50 percent.
Storage (indoor/outdoor)
This instrument should not be stored in any location where water entry to the instrument
could occur. Also, humidity will affect the operation of the instrument.
Shipment
All Baker testers are shipped using factory foam-filled containers. Should the tester be
returned to Baker Instrument Company, an SKF Group Company for any reason, we
recommend using the original packaging the unit came in or the following factory specified
packaging:
Contact Baker Instrument Company, an SKF Group Company to order factory-specified

packaging for your testers.
Foot Switch
The PP24 comes with a foot switch that plugs into the front panel of the instrument. This foot
switch takes the place of the Test button on the unit’s front panel. Often, it is convenient to
use the foot switch especially when making PI measurements.
Safety Lights
For those customers who use testing safety lights in their operations, a set of safety lights and
a remote test inhibit switch are provided with the instrument. These lights also plug into the
front panel near the foot switch.
There are two plastic boxes – the Light box houses a (flashing) red light and a green light, the
E-Stop box contains an E-Stop button as well as red & green indicator lights. These two
boxes can be used together or separately, For example, the E-Stop box can be used by itself.
The cables connecting the two boxes are interchangeable and the Light box can be connected
to the cables from either end.
12/7/2009 | 71-026 V2 8
PP24
CE Declaration of Conformity
Manufacturer’s Name & Address:
Baker Electrical Instrument Company, an SKF Group Company
4812 McMurry Ave
Fort Collins, CO 80525
USA
EC Representative’s Name & Address:

Baker Instrument GmbH
Hutbergstrasse 21
D-90475 Nurnberg
Germany
Equipment Description: Testers for Surge, DC Hi-Pot, and Winding Resistance of

motors.
Equipment Model Designations: PP124 and PP224.
Application of Council Directive 72/23/EC on the harmonization of the laws related

to Member States relating to electrical equipment designed for use within certain
voltage limits, as amended by: Council Directive 93/68/EC and Council Directive
2004/108/EC on the approximation of the laws related to Member States relating to
the electromagnetic compatibility, as amended by: Council Directive 93/68/EC. Note:
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.
Referenced Safety Standards:

EN 61010-1
Referenced EMC Standards:

EN 61326:2001
EN 55011 Class A
EN 61000-3-2
EN 61000-3-3
EN 61000-4-2
EN 61000-4-3
EN 61000-4-5
EN 61000-4-5
EN 61000-4-6
EN 61000-4-11
I, the undersigned, hereby declare that the equipment specified above conforms to
the above Directives and Standards.
Signature:
Printed Name: Mike Teska

Title: Engineering Manager.
12/7/2009 | 71-026 V2 9
PP24
12/7/2009 | 71-026 V2 10
PP24
1
Getting started
Fig 1-1: PP24 Front Panel 1
General Information
The PP24 is a booster pack for a Baker Instrument Company, an SKF Group Company host
surge tester that allows large high voltage motors, windings, and coils to be tested for
insulation integrity. The PP24 is ideal for testing large 4kV and 7kV class windings.
The PP24 cannot operate alone - a Baker AWA or DR host tester is required to operate the
PP24. The host has the brains to control the PP24 and can save the test data taken with the
PP24.
IEEE 522 IEC 34-15 EASA

Surge Test (for Chapter 13
HV form wound
only)
New In 1.2 x 50 0.2us In Service
Service
Vline 3.5*pu 75% of 4E+5000 65% 2E+1000
new
480 1372 1029 6920 4498 1960
575 1643 1232 7300 4745 2150
600 1715 1286 7400 4810 2200
2300 6573 4930 14200 9230 5600
4160 11888 8916 21640 14066 9320
6900 19718 14789 32600 21190 14800
13800 39437 29578 60200 39130 28600
How Does the PP24 Work?
The host unit is placed on top of the PP24 and the two units are connected with an interface
cable. Once the two machines are powered and operating, the host unit is configured to talk
12/7/2009 | 71-026 V2 11
PP24
Applicable Voltages and Standards
to the PP24. This configuration depends on which unit, AWA or DR, is being used and is
described in the chapters below.
A test is started with the PP24 by manipulating the controls on the PP24 only. No testing
controls on the host unit are used during a PP24 test. The test leads for the host unit should
be coiled up and placed on top of the host so that the host and PP24 test leads are separated
and not confused with each other.
The output voltage of the PP24 is manually controlled by the operator. Since the operator is
in full control of the PP24, care should be taken to ensure the testing environment is safe, the
test leads won’t accidentally shock a person (including the operator), and the test voltage is
not exceeded for the motor being tested.
During the test, the host unit records and display’s the PP24’s readings. Once a test is
finished, the PP24’s readings are saved in the host’s memory.
Recommended Test Voltages

There are several organizations that establish a test voltage for testing a motor winding: IEEE,
EASA, IEC, and NEMA. The table below shows surge testing voltages.
The easiest formula to remember is 2V+1000 which lands nicely in the middle of the IEEE
recommended voltages. The European IEC voltages are much higher than the test voltages
most often used in the US.
The HiPot test voltages are shown in the table below:

HiPot Test Voltages IEEE 95-1977 (Para 5.2 for maintenance proof testing)
EASA DC
HiPot
(Chapter 8)
IEEE 95 Min IEEE 95 New IEEE 95 Min
V Max V V
Vline Vline*1.25x1.7 Vline*1.5*1.7 3.4*Vline+1700 Vline Vline*1.25x1.7
480 1020 1224 3332 480 1020
575 1222 1466 3655 575 1222
600 1275 1530 3740 600 1275
2300 4888 5865 9520 2300 4888
4160 8840 10608 15844 4160 8840
6900 14663 17595 25160 6900 14663
13800 29325 35190 48620 13800 29325
NEMA MG-1-1987 NEMA MG-1-1987 DC

DC HiPot HiPot
New New
Acceptance Acceptance
Vline MG-1-20.48.2 MG-1 3.01.12 MG-1-20.48.2
(2E+1000)*1.7 75% of new (2E+1000)*1.7
480 3332 2499 3332
575 3655 2741 3655
600 3740 2805 3740
2300 9520 7140 9520
4160 15844 11883 15844
6900 25160 18870 25160
13800 48620 36465 48620
Again, the 2V+1000 formula gives a HiPot test voltage that nicely fits within many of the
industry practiced test voltages.
12/7/2009 | 71-026 V2 12
PP24
2
DC testing/DR unit
Danger
High Voltage



tested components.
up.
specifications.
12/7/2009 | 71-026 V2 13
PP24
DC Testing/DR Unit

DR DC Tests Operation
This chapter describes how to connect and operate a Baker Digital tester, abbreviated DR,
with the PP24. The DR tester must be calibrated to the specific PP24 being used. The
calibration stickers on both instruments will have the serial number of the instrument it is
calibrated to.
Place the DR unit on top of the PP24 and connect the interface cable to the two units. Coil up
the DR’s test leads and place them on top of the DR.
Connect AC power to both units. The DR can be powered from the short AC power cord from
the PP24. The PP24 is set up for either 120VAC or 240VAC (50 or 60Hz), but not both
voltages. The DR can use either 120 or 240VAC.
Fig 2-1: Digital main screen

1) Turn on both the PP24 and DR.
2) The DR will go through a memory test. When the memory test is finished,
3) Press the Clear button to initialize the DR’s display.
4) Move the Function knob on the DR to the AUX position as shown in Fig 2-2.
12/7/2009 | 71-026 V2 14
PP24
DC Testing/DR Unit
Fig 2-2: Function knob
5) Move the Function knob on the PP24 to the test desired – either the Surge position
for surge testing or 100uA/div for HiPot testing as shown in Fig 2-3.
Fig 2-3: Function switch
6) Connect the winding to be tested. Ensure safety.
7) Press and hold the Test button on the PP24 to start the test. The red Testing
lamp will illuminate showing a test is active.
8) Increase the test voltage using the PP24’s output control knob. If the control knob
was at a position other than zero when the Test button was pressed, the unit will
not enable until the knob is turned down to zero output.
9) Observe on the screen, record and save the test results to the tester.
Megohm/PI/HiPot testing
Before going into the DC tests with the PP24, it must be noted that the PP24 may require a
voltage regulator to stabilize the incoming power to the unit. If the incoming AC is not well
regulated, the output voltage of the PP24 will change along with any changes in the incoming
AC power. Varying AC power will cause the leakage current to vary to a degree that the
Megohm, PI and HiPot tests may not be accurate. If poor incoming power conditions prohibit
accurate readings, a power conditioner should be used to filter the incoming power to the
12/7/2009 | 71-026 V2 15
PP24
DC Testing/DR Unit
PP24. Also, very accurate Megohm and PI measurements can be made with the DR which
has a very tightly regulated high voltage power supply regardless of the quality of the
incoming power.
To perform Megohm/PI/HiPot testing with the PP24, ensure the two units are connected &
powered as described above, follow these instructions:
Fig 2-4: Single lead connection
1) Connect the single red test lead to the winding to be tested and at least one black
lead to the motor frame. A good practice is to connect all three black leads to the
motor frame.
2) Set the Function knob on the PP24 to 100uA/div
Fig 2-5: Function switch at 100 µA/Div
3) After insuring the testing environment is safe, press and hold the Test button.
4) Smoothly turn the output control knob up to the required test voltage. The output
voltage and leakage current will be displayed on the screen of the DR host. Do not
12/7/2009 | 71-026 V2 16
PP24
DC Testing/DR Unit
turn the output control knob so fast that the PP24 HiPot trips while charging the
motor’s ground wall capacitance.
5) Once the test voltage is reached, stop turning up the output control knob, set the
time to zero by pressing the T=0 button on the DR, and follow the instructions on
the DR’s display on changing the current range to the most sensitive range. The
test button must still be depressed for the entire test. Releasing the test button will
cause testing to stop.
6) As key times are reached during the test, values will appear on the screen. Once 60
seconds has passed per IEEE 43, press the Save Meg button on the DR to save the
Megohm reading. Note: the DR automatically acquires a HiPot reading at 1min/60s
- this value can also be used for the Megohm reading.
Fig 2-6: Megohm & 1 min DC test reading – test active
7) If a DA test is needed, continue to keep the Test button pressed. At 3min/180s, the
DR will automatically acquire the voltage and current readings and then will
calculate a 3min/30s DA Test as shown below.
Fig 2-7: DA ratio visible
12/7/2009 | 71-026 V2 17
PP24
DC Testing/DR Unit
Fig 2-8: Test active - Megohm, DA & PI values listed
8) If a PI test is wanted, keep the Test button depressed until the 10 minutes of the
PI test has elapsed. At 10 minutes, the readings for the PI test will automatically be
recorded.
9) If a HiPot test is desired, keep the Test button depressed, change the PP24’s
function knob to the 100uA/div (as shown below) and raise the output voltage to
the required HiPot test voltage.
Fig 5-9: HiPot 100 µA/Div
10) Once at the HiPot test voltage at p, note the time on the tester. Change the current
sensitivity on the tester as noted on the screen of the DR.
11) Once the required time for the HiPot test has elapsed, press the Save HiPot button
on the DR.
12/7/2009 | 71-026 V2 18
PP24
DC Testing/DR Unit
Fig 5-10: At DC test completion
12) Release the Test button and allow the voltage on the PP24’s test leads to drop to
zero before touching the test leads.
Fig 2-11: Storage Screen
13) To save the data just recorded, press the Store button on the DR and select a
record to save the data to. Use the Up and Down buttons to move to the record,
press the Select button to select the record. Once the DC Tests field is highlighted
and press Select again to store the data to the DR’s memory.
12/7/2009 | 71-026 V2 19
PP24
DC Testing/DR Unit
12/7/2009 | 71-026 V2 20
PP24
3
Surge testing/DR Unit
Fig 3-1: Lead connections
Danger
High Voltage



12/7/2009 | 71-026 V2 21
PP24
Surge Testing DR Unit
tested components.
up.
specifications.
b. Danger from loss of ground – Upon loss of the protective ground

Surge Testing with the PP24 and DR

Surge testing a three phase AC induction motor with the DR and a PP24 is done one lead at a
time. The PP24’s test leads are arranged as follows:
For testing Lead 1 / Phase A:

− Connect the single red test lead to the motor’s Phase A lead
− Connect one of the black test leads to the motor’s Phase B lead
− Connect a second black test lead to the motor’s Phase C lead
− Connect the third black test lead to the motor’s frame
− Perform the surge test with the PP24 (to be described in detail below)
− Save the waveform in a record under Lead 1 (again, to be described in detail below)
For testing Lead 2 / Phase B

− Connect the single red test lead to the motor’s Phase B lead
− Connect one black test lead to the motor’s Phase A lead
− Connect one black test lead to the motor’s Phase C lead
− Leave the third black test lead to the motor’s frame
− Perform the surge test with the PP24
− Save the waveform in a record under Lead 2
For testing Lead 3 / Phase C

− Connect the single red test lead to the motor’s Phase C lead
− Connect one black test lead to the motor’s Phase B lead
12/7/2009 | 71-026 V2 22
PP24

By moving the red test lead from one phase then to the next phase as described above, the
motor winding is completely surge tested.
The indication of an arcing turn-turn insulation failure is a jump to the left of the surge
waveform as the voltage is increased. The shift may also be accompanied by a slight drop in
the amplitude of the waveform. The shift can also be a very slight shift so it is important to
adjust the settings on the DR so the waveform fits the screen: if the screen is zoomed in too
far, the shift will be missed, if the screen is zoomed out to far the waveform will be so small
that the shift cannot be seen.
The indication of a welded turn-turn short is a waveform that never jumps to the left but
stays shifted to the left when compared to the other two waveforms. Usually, if one waveform
is shifted due to a welded fault, all three will be separated when compared to each other.
The details of performing a surge test will now be described (this discussion assumes both the
DR and PP24 are connected and powered up as described at the beginning of this chapter):
1) Turn the Function knob on the PP24 to the surge position.
Fig 3-2: Function switch at surge
2) Connect the red test lead as described above for testing Phase A.
3) Press and hold the Test button and smoothly ramp the voltage up manually with
the Output Control knob on the PP24.
4) Increase the voltage to 500-1,000V.
5) Adjust the Volts per Division knob on the DR so that the waveform fills the vertical
extent of the screen.
12/7/2009 | 71-026 V2 23
PP24
6) Adjust the Seconds per Division knob on the DR so the waveform fills the horizontal
extent of the screen.
7) At the fairly low voltage, the waveform should be well captured on the screen as
shown below.
Fig 3-3: Surge waveform
8) Continue to smoothly ramp the voltage up to the required test voltage. While
ramping, carefully watch the screen for a shift to the left of the waveform that is an
indication of the arcing turn to turn insulation failure.
9) Adjust the Volts per Division setting as the waveform grows on the screen. If
there’s a flat top on the waveform, adjust the Volts per Division knob to the next
higher position. (A message will be displayed on the screen instructing the operator
to increase the V/div setting.)
Fig 3-4: Division settings
12/7/2009 | 71-026 V2 24
PP24
10) The Seconds/div setting may also have to be increased as the waveform grows to
right of the screen
11) Once the target test voltage is reached, release the test button.
12) Set the PP24 output control knob to min to set the test lead voltage to zero.
Fig 3-5: Store screen - Surge
13) Save the waveform by pressing the Store button on the DR and selecting a record
to save the data. Select the Lead 1 location to save this waveform.
14) Connect the red test lead to the motor’s Phase B lead as described at the top of
this chapter.
15) Leaving the V/div and uS/div knobs in the position from the last test, press and hold
the Test button and ramp the voltage up again to the target test voltage.
16) While ramping up the voltage watch the DR’s screen carefully looking for a shift to
the left of the waveform that is an indication of an arcing turn-turn fault.
17) Once the test voltage has been reached, release the Test button.
18) Press the Store button to save the waveform for the motor’s Phase B waveform in
the Lead 2 memory location as was done above for Phase A / Lead 1.
12/7/2009 | 71-026 V2 25
PP24
19) Switch the red test lead to the motor’s Phase C lead as described above and repeat
the above steps.
20) Save the Phase C waveform to the Lead 3 memory location.
21) At the end of all three tests, an EAR (Error Area Ratio) can be calculated for the
three waveforms. (The EAR will be described later in this chapter.) The EAR is
calculated by pressing the Save button after all three waveforms have been saved.
Select the record chosen to store the waveforms and select the EAR Calc option.
22) Once the EAR is calculated, it can be saved by pressing the Save button.
Fig 3-6: EAR recorded
23) Once all the data has been saved for both the HiPot and Surge tests, a summary
report can be printed as shown below.
This report contains all of the data for the HiPot and surge tests. If resistance tests were also
performed with the DR, resistance data would also be shown. (The winding being tested in
the photographs above has a welded fault in Phase 1 which is giving the large shifts seen in
the wave pattern. The winding is a 6.9kV stator without the rotor – the waveforms should
have been nearly identical with no visible shift.)
Printing a Report
A report for all the data taken above can be printed by connecting the DR’s printer to the
parallel printer port. The most convenient report is the Summary report which is printed by
pressing the Recall button, selecting the record to be printed and pressing the Summary
button.
EAR
The Error Area Ratio (EAR) is a calculation that gives a quantitative measure of the difference
of two waveforms. Mathematically the formula is
12/7/2009 | 71-026 V2 26
PP24
Npts
∑ Abs ( F i
(1)
− Fi ( 2 ) )
EAR1− 2 = i =1
Npts
∑ Abs ( F
j =1
j
(1)
)
What the formula above does is calculate the ratio of the two areas shown in the two figures
to the right.
To summarize, the EAR is the pink area divided by the blue area.
The EAR algorithm is on the DR to calculate the Line to Line EAR (L-L EAR). The L-L EAR is
used to numerically quantify the difference between the three waveforms of a three phase
motor’s surge test.
Fig 3-7: Graphical EAR explanation
12/7/2009 | 71-026 V2 27
PP24
12/7/2009 | 71-026 V2 28
PP24
4
Testing with a AWA unit
Danger
High Voltage


tested components.
up.
specifications.
12/7/2009 | 71-026 V2 29
PP24
DC Testing AWA Unit

DC testing with an AWA
Fig 4-1: DC test screen AWA
This chapter describes how to use the PP24 with an Advanced Winding Analyzer (AWA). The
AWA tester must be calibrated to the specific PP24 being used. The calibration stickers on
both instruments will have the serial number of the instrument it is calibrated to.
1) Place the AWA unit on top of the PP24 and connect the interface cable to the two units.
Coil up the AWA’s test leads and place them on top of the AWA.
2) Connect AC power to both units. The AWAII can be powered from the short AC power
cord from the PP24. The AWAIII and AWAIV models will need a separate power cord
plugged into the same outlet as the PP24. The PP24 is set up for either 120VAC or
240VAC (50 or 60Hz), but not both voltages. The AWAII or AWAIII are also set up for
just one line voltage. The AWAIV can use either 120 or 240VAC. Turn on both the PP24
and AWA.
3) The AWA will boot Microsoft Windows. Start the AWA application (see the AWA User’s
Manual).
4) Create a new motor in the AWA software to be tested with the PP24 as described in the
AWA User’s Manual.
5) Create a new Test ID to define the test voltage and Pass/Fail criteria for testing the
motor. There are several predefined Test IDs for the larger motors that may be selected
as the Test ID for this motor.
6) The PP24 is considered a Power Pack, and, therefore, the Power Pack must be enabled
in the Test ID to operate. In the HiPot testing screen, check the Enable PP check box to
perform HiPot testing with the PP24.
12/7/2009 | 71-026 V2 30
PP24
DC Testing AWA Unit
7) With an AWA host, the PP24 is only used for the HiPot test. The Megohm, and PI tests
are all performed with the AWA.
Megohm/PI/Hipot Testing
Before going into the DC tests with the PP24, it must be noted that the PP24 may require a
voltage regulator to stabilize the incoming power to the unit. If the incoming AC is not well
regulated, the output voltage of the PP24 will change along with any changes in the incoming
AC power. Varying AC power may cause the leakage current to vary to a degree that the
HiPot current may fluctuate so much that good readings cannot be obtained. If this condition
exists, a voltage regulator will be required supply power to the PP24. The Megohm and PI
tests are run on the AWA which has a regulated high voltage power supply and is not
susceptible to power line fluctuations.
To perform a HiPot test with the PP24, assuming the two units are connected & powered as
described above, follow these instructions:
1) Navigate to the DC Tests screen (shown above).
2) Move the PP24’s Function knob to the 100uA/div position.
Fig 4-2: Single lead connection

3) Connect the red lead from the PP24 to one of the motor leads.
4) Connect at least one of the black test leads to the motor frame. Although only one black
ground lead is required, it is good practice to attach all three black leads to the motor
frame.
5) Insure the test area is safe and press and hold the PP24’s Test button.
6) While keeping the Test button depressed, increase the output voltage knob until the test
voltage defined by the Test ID is reached.
7) When the test voltage is reached, the AWA will start a timer that counts down to the
end of the test. If the test voltage accidentally increased significantly beyond the test
voltage, the AWA will shut down the test.
8) If and when the charging current drops below 80-90uA, move the Function knob to the
10uA/div position.
12/7/2009 | 71-026 V2 31
PP24
DC Testing AWA Unit
9) If and when the charging current drops below 8-9uA, move the Function knob to the
11uA/div position.
10) At the end of the test, the AWA will automatically shutdown the PP24. A Discharge Bar
will appear on the AWA screen. Wait until the Discharge Bar disappears before moving
or touching the test leads.
11) Close the DC Tests screen and save the data by selecting the yellow Save Data button
on the AWA.
12/7/2009 | 71-026 V2 32
PP24
5
Surge Testing/AWA
Danger
High Voltage



tested components.
up.
specifications.
12/7/2009 | 71-026 V2 33
PP24
Surge Testing AWA Unit

Surge Testing with the AWA and PP24

Surge testing a three phase AC induction motor with the AWA and a PP24 is done one lead at
a time. The PP24’s test leads are arranged as follows:
Fig 5-1: Lead connections
For testing Lead 1 / Phase A:

− Connect the single red test lead to the motor’s Phase A lead
− Connect one of the black test leads to the motor’s Phase B lead
− Connect a second black test lead to the motor’s Phase C lead
− Connect the third black test lead to the motor’s frame
− Perform the surge test with the PP24 (to be described in detail below)
− Save the waveform in a record under Lead 1 (again, to be described in detail below)
For testing Lead 2 / Phase B

− Connect the single red test lead to the motor’s Phase B lead
− Connect one black test lead to the motor’s Phase C lead
For testing Lead 3 / Phase C

− Connect the single red test lead to the motor’s Phase C lead
− Connect one black test lead to the motor’s Phase B lead
12/7/2009 | 71-026 V2 34
PP24
Fig 5-2: AWA surge screen
By moving the red test lead from on phase then to the next phase as described above, the
motor is completely tested.
The indication of an arcing turn-turn insulation failure is a jump to the left of the surge
waveform as the voltage is increased. The shift may also be accompanied by a slight drop in
the amplitude of the waveform. If the ppEAR (Pulse to Pulse EAR) feature of the AWA is
turned on, the AWA will most likely identify the arcing fault and may shut the test down. If the
ppEAR feature is turned off, the operator will have to closely monitor the waveform looking
for the jump to the left of the waveform that is the indication of the arcing fault.
T
he indication of a welded turn-turn short is a waveform that never jumps to the left but stays
shifted to the left of the other two waveforms. Usually, if one of the three waveforms is
shifted due to a welded fault, all three will be separated when compared to each other. If the
L-L EAR (Line to Line EAR) feature is turned on, the AWA software can fail the motor based
on the separation of the waveforms.
The details of performing a surge test will now be described (this discussion assumes both the
AWA and PP24 are connected and powered up as described at the beginning of this chapter):
Fig 5-3: Function knob PP24
1) Turn the Function knob on the PP24 to the surge position.
12/7/2009 | 71-026 V2 35
PP24
2) Connect the red test lead as described above for testing Phase A.
3) Navigate to the Surge Testing screen and enable the power pack as shown in Fig 5-3.
Select the Lead 1 button on the AWA screen and follow the directions.
4) Press and hold the PP24’s Test button and slowly ramp up the voltage. If the ppEAR
feature is turned on, the Output Control knob will have to be slowly and smoothly
increased. If the voltage is increased too quickly, the ppEAR may exceed is limits and the
test will be halted by the software.
5) The scale on the AWA’s screen will automatically be adjusted to fit the waveform (if
Auto scale is turned on).
6) Once the target test voltage is reached, the AWA software will stop the test.
7) Connect the red test lead to the motor’s Phase B lead.
8) Select the Lead 2 button on the AWA screen and follow the directions.
9) Press and hold the PP24’s Test button and slowly ramp up the voltage as done
previously for Lead 1.
10) When the test voltage is reached, the AWA software will again stop the test as described
above.
11) Switch the red test lead to the motor’s Phase C lead and repeat the above steps.
12) Select the Lead 3 button on the AWA screen and follow the directions.
13) Press and hold the PP24’s Test button and slowly ramp up the voltage as done
previously.
14) Once all three leads have been tested, close the Surge test screen and save the data by
selecting the yellow Save Data button on the AWA screen
Performing Complete Motors Tests with the AWA

A complete battery of tests can be made of a motor and the results saved in a single record in
the AWA’s database. This mode of operating the AWA is called Automatic even though the
PP24 is still manually controlled. (The test sequence is under control of the AWA software
and is considered an automatic test.)
1) To run an automatic test, configure a Test ID as required for the motor and select the
red Run Auto Test button on the AWA screen. At this point, just follow the directions as
the AWA software directs the test sequence. If a resistance test is selected in the Test
ID, the AWA software will direct the operator to hook up the appropriate host test leads
to the motor. If the Megohm / PI test has been selected, the software will again direct
the operator to connect the appropriate host test leads. If the PP24 is to do the Hipot
test, the software will direct the operator to disconnect the AWA’s test leads, and hook
up the PP24’s test leads. If the PP24 is to perform the Surge test, the software will
again direct the operator to connect the appropriate phases to the PP24. At the end of
the automatic tests, the test data will be saved automatically as done normally with
AWA tests.
2) Test data can be viewed and reports prepared just as with normal AWA operation.
Consult the AWA operator’s manual for more information.
12/7/2009 | 71-026 V2 36
PP24
Index
C O
CE Declaration of Conformity · 9 Operation · 6
Output Voltage · 7
D
P
DC testing with an AWA · 30
dielectric · 8 PI · 8, 15, 16, 18, 31, 36
Printing a Report · 26
E
R
EAR · 26, 27, 35
Environmental · 8 Recommended Test Voltages · 12
G S
Ground · 6 Safety · 8, 9
Surge · 9, 11, 15, 21, 22, 24, 26, 33, 34, 36
H
T
HiPot · 1, 12, 15, 16, 17, 18, 26, 31
Tests Operation · 14
M
Megohm · 15, 16, 17, 31, 36
12/7/2009 | 71-026 V2 37
PP24
Index
12/7/2009 | 71-026 V2 38
PP24

Baker Manual # 1

Caricato da

Informazioni sul documento

Descrizione originale:

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Baker Manual # 1

Caricato da

Copyright:

Formati disponibili

User’s Manual

DC HiPot/Surge Tester (Power Pack)

Baker Instrument Company, an SKF Group Company

Safety term definition

Other Important Safety warnings

2) For capacitor-started motors or systems with surge arrestors/power factor capacitors, be

3) Upon completion of a DC High Potential, Megohm, Polarization Index, Dielectric

a. Danger from loss of ground – Upon loss of the protective ground

9) This instrument is NOT waterproof or sealed against water entry.

Power Source Precautions

Ground the product

Earth (ground) terminal

Frame or chassis terminal. Located on rear panel of instrument by

Warning about hazardous voltage and risk of severe electrical shock or

Cleaning & decontamination

Technical assistance / Authorized Service Centers

Intermittent operation limits

1) Flat on the bottom of the unit,

There are no ventilation requirements.

Unpacking the unit

Power and utility

Contact Baker Instrument Company, an SKF Group Company to order factory-specified

EC Representative’s Name & Address:

Equipment Description: Testers for Surge, DC Hi-Pot, and Winding Resistance of

Application of Council Directive 72/23/EC on the harmonization of the laws related

Referenced Safety Standards:

Referenced EMC Standards:

Printed Name: Mike Teska

Fig 1-1: PP24 Front Panel 1

IEEE 522 IEC 34-15 EASA

Recommended Test Voltages

The HiPot test voltages are shown in the table below:

NEMA MG-1-1987 NEMA MG-1-1987 DC

Other Important Safety warnings

2) For capacitor-started motors or systems with surge arrestors/power factor capacitors, be

3) Upon completion of a DC High Potential, Megohm, Polarization Index, Dielectric

a. Danger from loss of ground – Upon loss of the protective ground

9) This instrument is NOT waterproof or sealed against water entry.

Fig 2-1: Digital main screen

3) Press the Clear button to initialize the DR’s display.

Fig 2-2: Function knob

Fig 2-3: Function switch

6) Connect the winding to be tested. Ensure safety.

Fig 2-4: Single lead connection

2) Set the Function knob on the PP24 to 100uA/div

Fig 2-5: Function switch at 100 µA/Div

Fig 2-6: Megohm & 1 min DC test reading – test active

Fig 2-7: DA ratio visible

Fig 2-8: Test active - Megohm, DA & PI values listed

Fig 5-9: HiPot 100 µA/Div

Fig 5-10: At DC test completion

Fig 2-11: Storage Screen

Fig 3-1: Lead connections

Other Important Safety warnings

2) For capacitor-started motors or systems with surge arrestors/power factor capacitors, be

3) Upon completion of a DC High Potential, Megohm, Polarization Index, Dielectric

b. Danger from loss of ground – Upon loss of the protective ground

9) This instrument is NOT waterproof or sealed against water entry.

Surge Testing with the PP24 and DR

For testing Lead 1 / Phase A:

For testing Lead 2 / Phase B

For testing Lead 3 / Phase C

− Perform the surge test with the PP24