Baker D30R Manuale utente

12/3/2009 | 71-022 V6

D30R

Users Manual

Digital Winding Tester

D30R

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.

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.

Warranty disclaimers

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D30R

Warranties; Disclaimers

Limited Warranty as to Baker/SKF

Brand Products.

a) 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.

b) 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.

c) 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.

Trademarks

All other trademarks, service marks or

registered trademarks appearing in this

manual are the trademarks, service

marks or registered trademarks of their

respective owners.

Table of Contents

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D30R

Users Manual ........................................................................................................................................... 1

Warranties; Disclaimers ......................................................................................................................... 2

Limited Warranty as to Baker/SKF Brand Products. .................................................................... 2

Trademarks .............................................................................................................................................. 2

Preface............................................................................................................................................................... 7

Important safety information.....................................................................................................................7

General Safety Precautions ...................................................................................................................7

Safety term definition.............................................................................................................................7

Other Important Safety warnings.........................................................................................................8

Symbols on equipment........................................................................................................................... 9

Other Information........................................................................................................................................9

Cleaning & decontamination..................................................................................................................9

Technical assistance / Authorized Service Centers ............................................................................ 9

Accessory interconnection and use ......................................................................................................9

Intermittent operation limits.................................................................................................................. 9

Installation requirements ....................................................................................................................... 9

Unpacking the unit .................................................................................................................................. 9

Pollution Degree II.................................................................................................................................10

Power requirements .............................................................................................................................10

Environmental conditions.....................................................................................................................10

Declaration of Conformity ........................................................................................................................11

1........................................................................................................................................................................13

Instrument Overview.....................................................................................................................................13

Front panel controls..............................................................................................................................13

Initial power-up and check-out...........................................................................................................16

Using the footswitch..............................................................................................................................16

2........................................................................................................................................................................17

Test sequence, voltages & applicable standards.......................................................................................17

Recommended testing sequence ........................................................................................................17

1) Coil Resistance test ..........................................................................................................................17

2) Megohm test .....................................................................................................................................17

3) Principles of the Dielectric Absorption (DA) test..........................................................................17

4) Principles of the Polarization Index (PI) test.................................................................................17

5) DC HiPot test.....................................................................................................................................18

6) Surge test ..........................................................................................................................................18

Recommended test voltages – HiPot and Surge tests....................................................................18

Applicable Standards ............................................................................................................................20

3........................................................................................................................................................................21

Coil Resistance testing ..................................................................................................................................21

Principles of Coil Resistance testing .......................................................................................................21

Resistance Test Display........................................................................................................................21

Resistance test checklist.......................................................................................................................21

Auto ranging Resistance measurement algorithm ..........................................................................22

Saving & recalling measurements......................................................................................................23

Indications of problems in a motor.....................................................................................................23

4........................................................................................................................................................................25

Principles and theory of DC testing.............................................................................................................25

Principles of DC testing.............................................................................................................................25

5........................................................................................................................................................................29

Performing high voltage DC tests ...............................................................................................................29

The test display..........................................................................................................................................29

Other Important Safety warnings.......................................................................................................30

General user notices .............................................................................................................................31

High voltage DC test checklist .............................................................................................................31

DC testing...........................................................................................................................................31

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D30R

Full DC testing of a motor....................................................................................................................31

Performing only a Megohm test.....................................................................................................34

Performing only DC over voltage test (DC HiPot test) ....................................................................34

Sample data showing good & poor insulation ..................................................................................35

Storing the test results in memory ....................................................................................................35

Using the footswitch..............................................................................................................................35

The HiPot over current trip indicator.................................................................................................35

Effects of temperature .........................................................................................................................36

Step Voltage test ...................................................................................................................................36

Step Voltage test procedure................................................................................................................36

6........................................................................................................................................................................39

Principles and theory of Surge testing .......................................................................................................39

Principles of Surge testing...................................................................................................................39

Surge testing theory .............................................................................................................................39

Determination of a fault.......................................................................................................................40

Motivation for Surge testing................................................................................................................41

Contact bounce......................................................................................................................................41

Lightening strikes ..................................................................................................................................41

Inverter transients.................................................................................................................................41

Line surges.............................................................................................................................................41

IGBT switching technology...................................................................................................................42

7........................................................................................................................................................................43

Performing Surge tests.................................................................................................................................43

Surge test display..................................................................................................................................43

Other Important Safety warnings.......................................................................................................44

General notices ......................................................................................................................................45

Surge test setup....................................................................................................................................45

Three phase motor check list ..............................................................................................................46

Single coil surge test and set-up........................................................................................................47

Example: Comparison to a master coil ..........................................................................................49

8........................................................................................................................................................................51

Surge test applications..................................................................................................................................51

Other Important Safety warnings.......................................................................................................51

Maintenance testing..............................................................................................................................52

Determination of a fault.......................................................................................................................53

Open Circuits..........................................................................................................................................53

Form coils ...............................................................................................................................................54

Notes and tips for form coils...........................................................................................................54

Three phase motors..............................................................................................................................54

Two or more single coils ......................................................................................................................55

Notices for two single coils ..............................................................................................................55

Wound rotor motors.............................................................................................................................55

Synchronous motor/generator............................................................................................................56

Faults in synchronous motor/generators ..........................................................................................56

Pole piece fault..................................................................................................................................56

Stator winding fault..........................................................................................................................56

Chiller motor testing .............................................................................................................................56

Field coils ................................................................................................................................................56

Armatures...............................................................................................................................................56

Bar-to-bar surge test ......................................................................................................................57

Span testing.......................................................................................................................................57

Determination of a fault...................................................................................................................58

Notes and tips for span testing armatures...................................................................................58

Testing large AC stators/motors .........................................................................................................59

Notes and tips for large AC stator/motors....................................................................................59

Rotor loading (coupling) when testing assembled motors..............................................................60

Testing assembled motors from the switchgear..............................................................................60

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D30R

Transformers .............................................................................................................................................61

Single phase transformers ..............................................................................................................62

Three phase transformers...............................................................................................................62

Determination of a fault...................................................................................................................62

9........................................................................................................................................................................63

Documenting tests.........................................................................................................................................63

Store........................................................................................................................................................63

Store Resistance data...........................................................................................................................64

Store HiPot and PI data .......................................................................................................................64

Store Surge data...................................................................................................................................64

Recall.......................................................................................................................................................66

Recall Resistance data..........................................................................................................................66

Recall HiPot data...................................................................................................................................67

Recall Surge data ..................................................................................................................................67

Print.........................................................................................................................................................68

Clear ........................................................................................................................................................68

Erase .......................................................................................................................................................68

Compatible printer information...........................................................................................................69

Appendix A Winding Faults...........................................................................................................................71

Appendix B......................................................................................................................................................73

Troubleshooting .............................................................................................................................................73

Notices for proper and safe operation ...............................................................................................73

Self help and diagnostics......................................................................................................................73

Step #1: Basic information................................................................................................................73

Step #2: Applications or service problem?......................................................................................73

Applications: What to do first!............................................................................................................74

Common application problems............................................................................................................74

Service: What to do first? ...................................................................................................................76

Open condition display..........................................................................................................................76

HiPot display checks..............................................................................................................................76

HiPot over current trip check ..............................................................................................................77

Open ground check ...............................................................................................................................77

Limited output surge waveform .........................................................................................................77

Warranty return ....................................................................................................................................77

Appendix C Technical specifications and calibration.................................................................................79

Technical specifications.............................................................................................................................79

Accuracy of measurements - Coil Resistance test...........................................................................79

HiPot measurement accuracy – HiPot voltage.................................................................................80

Testing Accuracy - HiPot Measurements..........................................................................................80

Voltage measurement accuracy – Surge (D30R).............................................................................80

Calibration information.........................................................................................................................80

Index ................................................................................................................................................................81

Table of Contents

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D30R

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.

Safety precautions, CE compliance

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D30R

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.

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

Dielectric absorption, or Continuous Ramp test, 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.

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.

Fig Pre-1: Safety Labeling D30R

Safety precautions, CE compliance

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D30R

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 D30R 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.

Accessory interconnection and use

The D30R are equipped with a footswitch standard. Please see details about these accessories

in later chapters in this manual.

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.

Safety precautions, CE compliance

12/3/2009 | 71-022 V6

D30R

Power cord

Operation manual

Pollution Degree II

(From IEC 61010-1 3.6.6.2) Only non-conductive pollution occurs. However, temporary

conductivity caused by condensation is expected.

Power requirements

Using the provided AC power cord, connect the unit to a grounded AC power source. The

unit’s power requirements are 100-240VAC, 50-60 Hz, 2 amps AC maximum current draw.

The unit is fused using 2.5A fast blow fuses. Replace fuses with like type and rating.

Environmental conditions

1) The unit has been tested for use up to 2000 m.

2) The tester should only be operated in temperatures ranging from 41 to 104

degrees Fahrenheit (5° C to 40° C).

3) This unit is for use at a maximum relative humidity of 80% for temperatures up to

31 °C decreasing linearly to 50% relative humidity at 40°C. This unit is intended for

Installation Category II in a Pollution Degree II environment.

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