1. DL manuals
  2. Baker
  3. Test Equipment
  4. D30R
  5. User's Manual & Operating Instructions

Baker D30R User's Manual & Operating Instructions

Other manuals for D30R: User Manual
Manual is about: Digital Surge/DC HiPot/Resistance Tester

Summary of D30R

  • Page 1

    D30r users manual 1 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 users manual digital surge/dc hipot/resistance tester models d30r baker instrument company 4812 mcmurry avenue fort collins, co 80525 (970) 282-1200 (970) 282-1010 fax (800) 752-8272 usa only www.Bakerinst.C...

  • Page 2

    D30r users manual 2 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 3

    D30r users manual 3 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 warranty baker instrument company (baker) warrants title to the product and also warrants product on date of delivery to purchaser to be of the kind and quality, merchantable and free of defects in workmansh...

  • Page 4

    D30r users manual 4 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 5

    D30r users manual 5 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 table of contents warranty ...................................................................................................... 3 preface.......................................................................

  • Page 6

    D30r users manual 6 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 auto ranging resistance measurement algorithm .................................... 37 saving & recalling measurements ............................................................ 37 indications of problems i...

  • Page 7

    D30r users manual 7 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 m aintenance t esting ................................................................................. 83 application notes .....................................................................................

  • Page 8

    D30r users manual 8 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 recall resistance data ............................................................................ 113 recall hipot data .................................................................................... ...

  • Page 9: Reface

    D30r users manual 9 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 p reface inside… • safety precautions • power source precautions • ground the product • terms and symbols • warranty notes • authorized service centers • training seminars • environment • shipment • list of ...

  • Page 10

    D30r users manual 10 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 11

    D30r users manual 11 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 safety precautions note: the general safety information presented here is for both operating and service personnel. Specific warnings and cautions will be found throughout this manual where they apply. • do...

  • Page 12

    D30r users manual 12 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 this product is intended to operate from a power source that applies 85-264 vac rms 50/60hz between the supply conductor or between either supply conductor and ground. Ground the product this product is gro...

  • Page 13

    D30r users manual 13 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 if there is a failure of the baker tester, regardless of whether it is under warranty or not, the customer should call the baker instrument company service department before returning the unit for repair . ...

  • Page 14

    D30r users manual 14 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 due to corrosion, humidity will affect the condition of the instrument’s components over time. The storage environment of this instrument should be less than 50% humid. The instrument certainly should not b...

  • Page 15: Hapter

    D30r users manual 15 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 c hapter 2: i nstrument o verview inside….. • front panel controls • initial tester power up & checkout.

  • Page 16

    D30r users manual 16 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 17

    D30r users manual 17 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 digital front panel diagram d30r 21.

  • Page 18

    D30r users manual 18 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 front panel controls 1) printer port parallel port for printing waveforms and summaries displayed by the digital tester. This port may also be used for interfacing with the motor test acquisition for window...

  • Page 19

    D30r users manual 19 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 7) open ground warning light when the ac line source is not properly grounded, the red open ground light will illuminate. The test set will power up, but high voltage will be withheld by internal electronic...

  • Page 20

    D30r users manual 20 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 of the test and the resultant resistance in mega-ohms is also displayed on the screen for reference. There are three positions associated with the hipot test. The three positions are 100ua/div, 10ua/div, an...

  • Page 21

    D30r users manual 21 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 15) output control this control adjusts the output voltage of the tester. Clockwise (cw) rotation increases output and counterclockwise (ccw) rotation decreased output. Full ccw is the min (minimum) point o...

  • Page 22

    D30r users manual 22 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 20) three phase selector switch (lower section) this switch enables the operator to connect all motor leads of a three phase winding to the tester to facilitate surge comparisons. 21) kelvin resistance test...

  • Page 23: Hapter

    D30r users manual 23 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 c hapter 2: r ecommended t est s equence , v oltages and t esting p recautions inside…. • recommended test sequence • coil resistance • megohm test • dielectric absorption (da) • polarization index (pi) • d...

  • Page 24

    D30r users manual 24 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 25

    D30r users manual 25 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 recommended testing sequence in order to test motors adequately and to have effective predictive maintenance programs, baker instrument company suggests using a specific test sequence. The general idea is t...

  • Page 26

    D30r users manual 26 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 3. Principles of the dielectric absorption (da) test the dielectric absorption (da) test is essentially a short-duration pi test and is usually intended for smaller motors. Larger motors whose insulation do...

  • Page 27

    D30r users manual 27 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 unfortunately, most the insulating materials developed recently (last 20 years) do not easily polarize. For example the newer inverter grade wires and epoxy resins do not readily polarize. As recommended in...

  • Page 28

    D30r users manual 28 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 recommended test voltages – dc hipot and surge tests a recommended test voltage for hipot testing a motor, generator or transformer is twice the ac line voltage plus 1000 volts. This test voltage is consist...

  • Page 29

    D30r users manual 29 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 ieee 522 surge testing v line per unit new 3.5* pu in service 75% of new 480 392 1372 1029 575 469 1643 1232 600 490 1715 1286 2300 1878 6573 4930 4160 3397 11888 8916 6900 5634 19718 14789 13800 11268 3943...

  • Page 30

    D30r users manual 30 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 iec 60034-1 (1999-08) consolidated edition, rotating electrical machines part i: rating & performance ed. 10.2 ieee 43-2000 recommended practice for testing insulation resistance of rotating machinery ieee ...

  • Page 31

    D30r users manual 31 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 ieee customer service 445 hoes lane p.O. Box piscataway, nj 08855-1331 phone: 1-800-678-ieee fax: 908-981-9667 reprints of nema standards are available from: national electrical manufacturers association (n...

  • Page 32

    D30r users manual 32 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 33: Hapter

    D30r users manual 33 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 c hapter 3: c oil r esistance t esting inside: • principles of coil resistance testing • resistance test display • resistance test checklist • auto ranging resistance measurements • saving & recalling measu...

  • Page 34

    D30r users manual 34 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 35

    D30r users manual 35 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 principles of coil resistance testing the coil resistance test is a very simple test to perform and is an immediate indication of the health of the conductor(s) in a winding. The coil resistance test consis...

  • Page 36

    D30r users manual 36 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 resistance test checklist 1. Disconnect the high voltage test leads and move them aside. Baker tester resistance test circuitry is protected internally by relays, which ground the resistance test leads when...

  • Page 37

    D30r users manual 37 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 10. When the test is complete, connect the resistance test leads to leads 3 and 1 of the motor. 11. Set the function knob to res 3-1. 12. Again, press the run test button to begin another resistance test. 1...

  • Page 38

    D30r users manual 38 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 2. Use the up and down keys to select the appropriate record to store the test in. 3. Press select. The tester then displays a clear test screen. 4. To recall the record, select recall. 5. The record screen...

  • Page 39: Hapter

    D30r users manual 39 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 c hapter 4: p rinciples & t heory of dc t esting inside….. • principles of dc testing • principles of the megohm test.

  • Page 40

    D30r users manual 40 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 41

    D30r users manual 41 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 principles of dc testing high voltage dc testing of electric motors is performed in order to determine the integrity of the ground wall insulation system of a motor’s coil. The ground wall insulation system...

  • Page 42

    D30r users manual 42 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 current leakage measured voltage applied ir = motor’s steel core plus any surface leakage currents. The surface leakage currents flow through moisture or contaminants on the surface of the insulation. To ac...

  • Page 43

    D30r users manual 43 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 min) 1 ( min) 10 ( ir ir pi = in general, insulators that are in good condition will show a “high” polarization index while insulators that are damaged will not. Ieee 43 recommends minimum acceptable values...

  • Page 44

    D30r users manual 44 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 ir(3min) da = ir(30s) there are no accepted minimum or maximum values of the da test. However, the da value is considered to be trendable. Any change in the da value indicates that something is changing in ...

  • Page 45: Hapter

    D30r users manual 45 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 c hapter 5: p erforming h igh v oltage dc t ests inside….. • the test display • general user cautions & notes • test precautions • high voltage dc test checklist • dc testing • full dc testing of a motor • ...

  • Page 46

    D30r users manual 46 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 47

    D30r users manual 47 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 the test display fig 5-1: test display a. Main menu for function buttons and message area. B. Time duration of dc tests: c. Voltage bar d. Current bar e. Results from 30 sec, 1min, 3 min, 10 min, pi, da moh...

  • Page 48

    D30r users manual 48 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 • when increasing the applied voltage during a test, use a higher volts/div setting so the entire trace stays visible on the screen. It is acceptable to change this setting while testing. The volts/div cont...

  • Page 49

    D30r users manual 49 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 if the particular motor is a synchronous type or a dc machine, remove brushes, slip rings, etc. Before beginning the test. It is the operator’s responsibility to know what is being tested. Note: use caution...

  • Page 50

    D30r users manual 50 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 2. Move test lead selector switch to “hipot” position. Fig 5-3: digital unit front panel view 3. Move function knob to the 100ua/div position. 4. Press and hold “test” button. The “test” button needs to be ...

  • Page 51

    D30r users manual 51 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 two values are required for calculation of the da and pi tests. The tester automatically acquires these values. Fig 5-4: test active to 60 seconds 8. Continue to press and hold “test” button. In the screen’...

  • Page 52

    D30r users manual 52 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 9. After 10 minutes of continual testing, the tester will automatically acquire and display the leakage current. The pi ratio will be automatically calculated and displayed. Fig 5-6: test active 10 minutes ...

  • Page 53

    D30r users manual 53 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 fig 5-7: dc tests complete 14. Save test results by pressing the “store” button and selecting desired record. Performing only a megohm test 1. Connect appropriate high voltage leads to stator windings. 2. M...

  • Page 54

    D30r users manual 54 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 3. Move function knob to 100ua/div position. 4. Press and hold “test” button. Ramp test voltage to desired megohm test voltage and press the “time=0” button at the top of the screen after reaching required ...

  • Page 55

    D30r users manual 55 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 6. After time has elapsed for the dc over voltage test, usually 60 seconds per ieee 95, press the “save meg” button. Megohm data will be displayed in the middle of the screen between the voltage and current...

  • Page 56

    D30r users manual 56 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 fig 5-13: sample data-good insulation with high voltage and low leakage current. Fig 5-14: sample data - poor insulation with low voltage and high leakage current. Storing the test results in memory 1. Pres...

  • Page 57

    D30r users manual 57 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 2. Select the desired record to store the data by pressing the function keys corresponding to the up and/or down to bring the cursor to the desired record and pressing “select”. 3. Highlight “hipot” or “pi”...

  • Page 58

    D30r users manual 58 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 the hipot over current trip indicator the digital tester is equipped with an auto-ranging hipot over-current safety trip. If the hipot current levels exceed: • ~900ua in the 100ua/div range, • ~90ua in the ...

  • Page 59

    D30r users manual 59 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 step voltage test another test that can be performed using the digital tester is the step-voltage test. This test is used to indicate the condition of winding insulation by observing the linearity of leakag...

  • Page 60

    D30r users manual 60 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 6. Move function knob to the 100ua/div setting and increase voltage to 4000 volts. 7. Change ua/div range to best match the observed leakage current. 8. At the end of the next minute (2 min after start of t...

  • Page 61: Hapter

    D30r users manual 61 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 c hapter 6: p rinciples and t heory of s urge t esting inside….. • principles of surge testing • surge testing theory • determination of a fault • motivation for surge testing • contact bounce • lightening ...

  • Page 62

    D30r users manual 62 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 63

    D30r users manual 63 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 principles of surge testing surge testing is performed to detect insulation damage between turns within a motor’s winding. This type of insulation problem cannot be found any other way than by surge testing...

  • Page 64

    D30r users manual 64 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 is the primary one.) the coil becomes one of two elements in what is known as a tank circuit – a lc-type circuit made up of the coil’s inductance (l) and the surge testers internal capacitance (c). Inductan...

  • Page 65

    D30r users manual 65 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 determination of a fault if a fault exists in a motor, the wave pattern on the display will collapse in amplitude and a distinct shift to the left will occur, signifying an increase in frequency (a decrease...

  • Page 66

    D30r users manual 66 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 • inverter drive transients. • line surges caused by other motors or transformers tripping in the power system. One of the primary functions of a baker tester is to closely simulate the transient voltages s...

  • Page 67

    D30r users manual 67 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 voltage spikes manifest this energy impressed on the power system. These spikes are again, a source of damage to motors, especially if the motor already has weakened insulation. Igbt switching technology in...

  • Page 68

    D30r users manual 68 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 69: Hapter

    D30r users manual 69 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 c hapter 7: p erforming s urge t ests inside….. • surge test display • surge test setup • 480v 3 phase motor check list • single coil surge test and setup.

  • Page 70

    D30r users manual 70 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 71: Surge Test Display

    D30r users manual 71 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 surge test display fig 7-1: surge test display a. Main menu b. Digital peak voltage readout c. Number of surge pulses applied to the test winding d. Example of a surge wave pattern e. Volts/div setting, cur...

  • Page 72

    D30r users manual 72 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 • when increasing the applied voltage during a test, use a higher volts/div setting so the entire wave pattern or trace stays visible on the screen. It is acceptable to change this setting while testing. Th...

  • Page 73

    D30r users manual 73 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 1. Connect the motor as shown in one of the figures above. Connect phase 1 to test lead 1, phase 2 to test lead 2, phase 3 to test lead 3, and the motor core to the black ground lead. Note: these connection...

  • Page 74

    D30r users manual 74 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 480v three phase motor check list check to ensure there is nothing connected to the coil or winding being tested. This is extremely important when testing installed coils or windings. Test inaccuracies will...

  • Page 75

    D30r users manual 75 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 test voltage of 4000v, a setting of 500 volts/div would result in a wave pattern with 8 divisions amplitude which would go off the screen. 10. Watch the surge waveform display while the voltage is increasin...

  • Page 76

    D30r users manual 76 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 12. Move the test lead selector switch to lead 3. 13. Repeat steps 5 through 8 for lead 3 and again save the data in the testers memory as was done in step 12. Note: a good way to check the wave patterns af...

  • Page 77

    D30r users manual 77 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 setting of 500 will give a wave pattern with 4 divisions of amplitude that does not go off the screen. For a test voltage of 4000v, a setting of 500 volts/div would result in a wave pattern with 8 divisions...

  • Page 78

    D30r users manual 78 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 2. Press the key corresponding to quick store. The wave pattern is now stored in record #1, lead #1 and is immediately recalled on the screen. B. Store the pattern conventionally if the tests are to be down...

  • Page 79

    D30r users manual 79 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 occasionally, a manufacturer may want to test against a standard. The selected standard coil is surge tested, results are stored in memory and recalled to the screen. Quick store is useful for this situatio...

  • Page 80

    D30r users manual 80 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 81: Hapter

    D30r users manual 81 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 c hapter 8: s urge t est ap plications inside….. • maintenance testing • single phase motors and two terminal divices • form coils • three phase motors • two or more single coils • wound rotor motors • sync...

  • Page 82

    D30r users manual 82 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 83

    D30r users manual 83 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 note: for additional reference for fault determination see typical winding faults. Note: if all three wave pattern comparisons in surge testing show considerable separation when testing three phase windings...

  • Page 84

    D30r users manual 84 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 consider a 460v ac motor. The operating voltage is the root mean square, a kind of average, of the ac power supply. For this motor, multiply 460v by 1.4 to determine the maximum voltage level that the coil ...

  • Page 85

    D30r users manual 85 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 checked by firmly grasping the boot and clip in one hand while pulling on the lead with the other. A broken lead will stretch. A good lead will not stretch. Fig 8-2: open phase in lead in a wye-connector mo...

  • Page 86

    D30r users manual 86 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 fig 8-3: good coil & bad coil if any wave pattern becomes erratic and/or flickers during testing, intermittent shorting or arcing is probably occurring in the windings under the voltage stress. Arcing is of...

  • Page 87

    D30r users manual 87 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 • currents required to test form coils often limit the maximum surge voltage. Placement of the coils into the stator iron or spare laminations has the effect of enabling the tester to produce a higher volta...

  • Page 88

    D30r users manual 88 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 4. Perform the test as described in three phase motor surge test and set-up. For each test, check the display for a wave pattern. Recall a summary from the digital tester’s memory for wave patterns for the ...

  • Page 89

    D30r users manual 89 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 2. Connect test lead #2 to the second coil or identical coils and connect test lead #3 to that coil’s other side. 3. Surge test the first coil with the tls in position #1. Store the results in memory. Note:...

  • Page 90

    D30r users manual 90 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 pole pieces, one of which is making better magnetic contact with the rotor then the comparing pole. For this reason it is recommended that devices like pole pieces be evaluated individually and not compared...

  • Page 91

    D30r users manual 91 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 3. Surge test the stator as would be done on a three phase induction motor. See three phase stators or follow the directions in three phase motor surge test and setup. Note: since the rotor is shorted out t...

  • Page 92

    D30r users manual 92 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 synchronous motor/generator the synchronous stator is tested as a three phase induction motor. The rotating fields should be tested individually. 1. Before surge testing the stator. A. Remove the dc leads t...

  • Page 93

    D30r users manual 93 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 frequency ( a decrease in inductance). This type of fault is usually failure of the turn-to-turn insulation. Stator winding fault for a stator winding fault, if the wave pattern changes and becomes erratic ...

  • Page 94

    D30r users manual 94 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 armatures there are two methods of surge testing armatures: the bar-to-bar surge test and the span surge test. The use of a footswitch is highly recommended to ease the operation of these tests. Bar-to-bar ...

  • Page 95

    D30r users manual 95 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 the wave pattern produced in this test represents the voltage oscillation between the tester and the coils for the specific number of commutator bars spanned. For example, any 10 bars spanned in series on t...

  • Page 96

    D30r users manual 96 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 note : the zero start interlock is disabled only when the funtion switch is set to at101 for the at101d accessory (see supplement #: model at101d) and the footswitch is depressed. Without the accessory and ...

  • Page 97

    D30r users manual 97 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 fig 8-5: fault located under the ground brush fault grounded under the hot brush or outside of the surge test span notes and tips for span testing armatures • a test fixture can be used in place of using th...

  • Page 98

    D30r users manual 98 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 low inductive load may cause difficulty achieving the desired test voltage and a good ringing wave pattern on the screen. • to simulate a fault, use an insulated screwdriver to temporarily short two commuta...

  • Page 99

    D30r users manual 99 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 fig 8-6: seconds/div set too far cw seconds/div adjusted ccw to correct for this display condition turn the seconds/div control counter- clockwise, slowing the sweep rate. The correct surge wave pattern wil...

  • Page 100

    D30r users manual 100 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 rotor loading (coupling) when testing assembled motors when testing assembled motors, the rotor can influence the shape of the surge wave pattern. These influences are as follows. 1. Loss of wave pattern a...

  • Page 101

    D30r users manual 101 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 detailed instructions for surge testing and storage and print capabilities for discussions of the storage and recall functions. 1. Surge test phase #1 of the motor. Store and recall the wave pattern by usi...

  • Page 102: Warning!

    D30r users manual 102 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 testing assembled motors from the switchgear the surge and hipot tests are valid tests when testing from the switchgear at the motor control center. Not only are the windings of the motor tested, but the i...

  • Page 103

    D30r users manual 103 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 • the surge test circuit will be loaded by the feeder cable capacitance as well as the motor. Significantly higher output settings will be needed to reach the required test voltage. If the surge tester is ...

  • Page 104

    D30r users manual 104 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 fig 8-9: single phase transformer connections 3. Surge test the winding following the procedures outline for single phase motors and two terminal devices. The discussion of determining a fault applies. Not...

  • Page 105

    D30r users manual 105 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 3. Follow one of the charts below for connections for wye-wye or delta- wye transformers. The transformer windings should be surge tested for all the configurations shown. 4. Test procedures follow identic...

  • Page 106

    D30r users manual 106 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 107: Hapter

    D30r users manual 107 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 c hapter 9 d ocumenting t ests inside…… • test data storage • recalling test data • printing reports • compatible printers.

  • Page 108

    D30r users manual 108 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 109

    D30r users manual 109 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 the digital tester comes equipped with a microcontroller based hardware that allows the user to digitize, store, recall and print test data for up to 10 motors or windings. This applies to surge and dc hip...

  • Page 110

    D30r users manual 110 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 store record submenu options qwk str up down select qwk str represents quick store. The wave pattern or hipot/pi data that is currently on the display is automatically stored in memory of the selected reco...

  • Page 111

    D30r users manual 111 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 store hipot and pi data if the tester is currently in the hipot mode, the next display will allow the user to choose whether to store hipot or polarization index data into memory. Fig 9-2: store hipot & pi...

  • Page 112

    D30r users manual 112 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 store surge data if the tester is currently in the surge mode, the display will allow the user to choose the lead location in memory for surge tests. Three lead locations are available for each record. Fig...

  • Page 113

    D30r users manual 113 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 recall recall is used to retrieve measurements from internal memory to the display. Choosing recall reveals a list of memory locations available for resistance, hipot and surge tests. Ten available record ...

  • Page 114

    D30r users manual 114 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 fig 9-4: recall resistance data recall hipot data if the tester is currently in hipot mode, the tester will display the recorded hipot and polarization index data for the selected record. Fig 9-5: recall h...

  • Page 115

    D30r users manual 115 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 recall surge data if the tester is currently in surge mode, the next display allows the user to choose the lead location from which to recall a wave pattern. Three lead locations are available for each rec...

  • Page 116

    D30r users manual 116 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 motor surge test and set-up, step 9 for procedures to compare two surge wave patterns simultaneously. Print print will print the record currently on the display. Clear clear will remove or blank out the wa...

  • Page 117

    D30r users manual 117 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 compatible printer information the hp printer support includes those hp printers that use the hewlett-packard pcl 3 printer language/command set. A non-inclusive list of compatible printers follows: • 500c...

  • Page 118

    D30r users manual 118 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 119: Ppendix

    D30r users manual 119 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 a ppendix a: t ypical w inding f aults inside…. • typical winding faults.

  • Page 120

    D30r users manual 120 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 121

    D30r users manual 121 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 for initial determination of winding faults, refer to the following figures. These wave patterns are typically seen for three phase, wye-connected, lap-wound induction stators. They provide a reference for...

  • Page 122

    D30r users manual 122 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 note: if all three wave pattern wave comparisons surge testing show considerable separation when testing three phase windings, the motor has a phase-to-phase short. Because two phases are faulty, a good wa...

  • Page 123: Ppendix

    D30r users manual 123 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 a ppendix b: t roubleshooting inside… • self help & diagnosis • applications – what to do first • common application problems • service: what to do first • hipot display checks • hipot over current trip ch...

  • Page 124

    D30r users manual 124 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 125

    D30r users manual 125 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 please review this section before calling baker instrument company or returning the unit. Self help and diagnostics problems in testing often crop up. If a problem is being experienced and the problem migh...

  • Page 126

    D30r users manual 126 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 if you can not say the problem is associated with any one type of motor/generator, or other coil type, then service would be involved. See service: what to do first! Applications: what to do first! Review ...

  • Page 127

    D30r users manual 127 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 varying degrees. There may not be separation throughout the whole wave pattern. This situation can be seen in dc fields or rotating poles. Be sure the coils being compared are being tested in identical con...

  • Page 128

    D30r users manual 128 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 slide the rubber test lead boots back, remove the old clip and replace the clips with the new ones. 7. How and why to test from the motor’s star point. When testing very large, high capacity motors, it may...

  • Page 129

    D30r users manual 129 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 nose pliers. Baker specifies the following fuse rating: 5x20mm 250v 2.5a slow-blow. 12. The screen shows a wavy appearance when the unit is at or near maximum output surge test voltage. The ac power source...

  • Page 130

    D30r users manual 130 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 hipot display checks the hipot display shows only the voltage or current bar. One of three problems might exist. • the item being tested is in fact faulty and has either low insulation resistance or open c...

  • Page 131

    D30r users manual 131 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 open ground check the open ground warning prevents testing. Answer these questions: 1. Has the unit recently been moved to a new location with possibly an ungrounded outlet? 2. Is the unit being operated i...

  • Page 132

    D30r users manual 132 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 precautions for proper operation • never raise the output control to attain a display from a blank screen! • never attempt “simulated” problems by disconnecting the leads and positioning them to arc agains...

  • Page 133

    D30r users manual 133 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 warranty return form please fill out all the following information and return this form with the tester. Make a copy for your records before sending this to baker instrument company. Note: be sure to follo...

  • Page 134

    D30r users manual 134 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 135: Ppendix

    D30r users manual 135 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 a ppendix c: t echnical s pecifications and c alibration p rocedure inside….. • d12r/d6r technical specifications • accuracy of measurements – coil resistance test • testing accuracy – hipot measurements •...

  • Page 136

    D30r users manual 136 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 137

    D30r users manual 137 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 technical specifications model d3r surge test output voltage 0-30000 volts max output current 1800-2000 amps pulse energy 45 joules discharge capacitance .1 micro-farad sweep range 2-2000µ seconds volts/di...

  • Page 138

    D30r users manual 138 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 accuracy of measurements - coil resistance test approximate range resistance resolution full scale accuracy 140 Ω - 20 Ω 1 Ω +/- 5% 20 Ω - 2 Ω 100m Ω +/- 5% 2 Ω - .2 Ω 2 m Ω +/- 5% .2 Ω - .020 Ω 2 m Ω +/- ...

  • Page 139: Ndex

    D30r users manual 139 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 i ndex.

  • Page 140

    D30r users manual 140 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007.

  • Page 141: High Voltage Dc

    D30r users manual 141 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 a applicable standards · 25, 31 c coil resistance · 27, 37 contact bounce · 68 crt display · 20 d dielectric absorption · 28 e environmental · 15 f fault · 67, 80, 87, 88, 90, 91, 93, 94, 95, 98, 99, 107 f...

  • Page 142

    D30r users manual 142 do not touch test leads while test is in progress! 71-023 rev c 5/8/2007 o on/off · 20 open ground warning light · 21 output control · 23 p pi test · 44, 45 polarization index · 44, 45 printer port · 20 r resistance · 1, 16, 25, 27, 32, 35, 37, 38, 39, 112, 115, 118, 140 s safe...