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Principles of High Voltage DC Testing

12/3/2009 | 71-022 V6
D30R

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Summary of Contents for D30R

Page 1: ...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 nearb...

Page 2: ...s 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 accessor...

Page 3: ...ower 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 Diel...

Page 4: ...nt 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...

Page 5: ...oper 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 Wh...

Page 6: ...Table of Contents 12 3 2009 71 022 V6 D30R 6...

Page 7: ...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 avoide...

Page 8: ...zed 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...

Page 9: ...ace 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...

Page 10: ...equirements 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 tes...

Page 11: ...ive 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...

Page 12: ...Safety precautions CE compliance 12 3 2009 71 022 V6 D30R 12...

Page 13: ...tailed description of the tester s storage capability 3 CRT display The Cathode Ray Tube CRT is the location where the tester displays test information At the Top menus corresponding to the four funct...

Page 14: ...ty of the DC HiPot leakage current display The name of the test chosen is displayed on the lower portion of the CRT for reference There are four primary positions as follows Aux The auxiliary position...

Page 15: ...urn the output control to MIN each time before pressing the Test button 6 In other words if the Test button is pressed while the Output control is above zero the instruments output is disabled until t...

Page 16: ...the unit 1 Check that the On Off switch is in the Off position 2 Connect the tester power cord to a 110 120 VAC outlet or 220 240 VAC outlets if appropriate The tester will work on either 60 Hz or 50...

Page 17: ...insulation in the motor If a low Megohm value is measured the motor should be inspected for ground wall insulation damage Some part of the ground wall insulation has failed Possible problems include 1...

Page 18: ...here are no accepted values for the DA However some usefulness can be obtained by trending the DA value over time 5 DC HiPot test A DC HiPot test is performed using a test voltage that is substantiall...

Page 19: ...4E 5000 0 2us 65 480 392 6920 4498 575 469 7300 4745 600 490 7400 4810 2300 1878 14200 9230 4160 3397 21640 14066 6900 5634 32600 21190 13800 11268 60200 39130 Baker Instrument Company an SKF Group Co...

Page 20: ...or Coils IEEE 432 1992 Guide for Insulation Maintenance for Rotating Electrical Machinery 5hp to less than 10 000hp IEEE 434 1973 Guide for Functional Evaluation of Insulation Systems for Large High V...

Page 21: ...more information on correcting resistance measurements to 25o C Since the windings found in many motors have very low resistances the injected current might have to be as high as 10 amps to accurately...

Page 22: ...will make another auto ranging resistance measurement and the result will be displayed on the tester s screen At the end of the test press the Store button to save the resistance measurements to the B...

Page 23: ...ons of problems in a motor If the resistance readings are significantly different from the motor nameplate data or a single lead is more than a few percent different from the others there is probably...

Page 24: ...Coil Resistance Testing 12 3 2009 71 022 V6 D30R 24...

Page 25: ...hen calculates the resulting insulation resistance IR using Ohm s law The Megohm Test consists of applying a DC voltage to the windings of a machine after first isolating the winding from ground The t...

Page 26: ...mplete The PI value is calculated by dividing the IR at 10 minutes by the resistance at 1 minute as shown below In general insulators that are in good condition will show a high polarization index whi...

Page 27: ...r voltage usually more than twice the voltage of the machine s operating voltage Therefore the HiPot test is often called a Proof test The insulation resistance value at the high applied voltage is no...

Page 28: ...Principles of High Voltage DC Testing 12 3 2009 71 022 V6 D30R 28...

Page 29: ...Measurement Current Measurement g Volts Div Setting Current Test Name Amps Div Setting Danger High Voltage To prevent serious injury or death Do not use in explosive atmospheres Do not contact test le...

Page 30: ...or powered up 15 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 to...

Page 31: ...test leads to the motor at the same time High voltage DC test checklist DC testing As explained earlier in Chapter 2 the Megohm test gives a quantitative measure of insulation resistance IR and is pe...

Page 32: ...d voltage 6 Adjust A div knob if required to get machine in the most accurate current range for reading leakage current The DR Series tester will display a message on the screen if the knob should be...

Page 33: ...display the leakage current The PI ratio will be automatically calculated and displayed 10 Continue to press and hold Test button and turn Function knob to 100uA div position 11 Ramp test voltage to d...

Page 34: ...ider bars Data acquired at 30 seconds and at 1 minute will be displayed These two values are required for calculation of the DA and PI tests The tester automatically acquires these values however if o...

Page 35: ...cord and pressing Select 3 Highlight HiPot or PI on the CRT screen using the Up and Down soft keys and press Select The leakage current and applied voltage will be saved in the system s internal memor...

Page 36: ...on resistance Megohm value is 5000Mohms at 30o C the compensated IR value at 40o C is 2500Mohms Step Voltage test Another test that can be performed using the Digital tester is the Step Voltage test T...

Page 37: ...nute three minutes after test start note the resistance reading 12 Again move Function Knob to the 100uA div setting and then increase voltage to 20 000 volts 13 Change A div knob to best match the ob...

Page 38: ...High Voltage DC Testing 12 3 2009 71 022 V6 D30R 38...

Page 39: ...t The indication of a turn to turn fault is a shift to the left and or a decrease in amplitude of the surge test waveform as the test voltage is increased Surge testing theory As mentioned above very...

Page 40: ...all testing is also performed in a surge test when there is a ground line to the machine frame The Surge test is most often used to test turn to turn insulation of coils or single windings Form coils...

Page 41: ...g the current an inductive kick back voltage spike will be developed Large inrush currents along with the high inductance of electric motors are what give these kick back voltage spikes their high ene...

Page 42: ...These IGBT devices are very fast switching transistors These are often found in variable speed motor drives and are used in the D30R in much the same manner as in the drives However Baker Instrument...

Page 43: ...ent Test Name Seconds Div setting F output 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...

Page 44: ...owered up 25 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...

Page 45: ...to Test Lead 3 and the motor core to the black ground lead Note these connections are the same as for the HiPot tests of Chapter 5 To HiPot and Surge Test a motor the test leads only need to be connec...

Page 46: ...ating surge pulses and the waveform is shown on the display The trace for the waveform may be moved up and down and left and right using the Horizontal and Vertical position controls on the front pane...

Page 47: ...t corresponds to Recall Press the Up and or Down keys to bring the cursor to the desired Record and press the key that corresponds to Summary Stored data for all three lead locations appear on the dis...

Page 48: ...2 If the surge wave pattern appears steady and stable the winding insulation is sufficient to withstand the applied voltage and the test is successful Note If the wave pattern begins to flicker or rap...

Page 49: ...ts of up to ten motors can be stored on the Digital tester In summary for each direction the coil is tested check the display for the wave pattern produced in each test If there are two good stable pa...

Page 50: ...Surge Testing 12 3 2009 71 022 V6 D30R 50...

Page 51: ...l shock or death 31 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 vo...

Page 52: ...terproof or sealed against water entry 40 The unit is for indoor use If used outdoors the unit must be protected from rain snow and other contaminants Maintenance testing The following are guidelines...

Page 53: ...ppear as the voltage is increased Determination of a fault If a wave pattern becomes erratic and or flickers during testing intermittent shorting or arcing is probably occurring in the winding Arcing...

Page 54: ...orm wound coils These are generally based on experience and theoretical arguments about the distribution of voltage in a coil and the entire winding Some of these formulas are difficult to apply becau...

Page 55: ...d when testing a two terminal device Shunt coils often have a small error in turns count Some mismatch or separation of patterns should be acceptable If the wave patterns are very close in shape and r...

Page 56: ...t For a stator winding fault if the wave pattern changes and becomes erratic during the test then intermittent shorting or arcing is occurring in the winding under test Steady separation of the wave p...

Page 57: ...ed As the armature is rotated all the commutator segments and therefore their respective coils pass into the test area between the hot surge test lead and the GRD lead Note It is important that the sa...

Page 58: ...bar directly below the hot brush is the faulty bar Notes and tips for span testing armatures A test fixture can be used in place of using the motor s brushes to make contact with the armature Set the...

Page 59: ...the winding To correct for this display condition turn the Seconds Div control counter clockwise slowing the sweep rate The correct surge wave pattern will always extend below the zero line Observe t...

Page 60: ...It is most prevalent in smaller high efficiency motors with small tolerance air gaps Separation of wave patterns that are due to rotor coupling can be determined when the wave patterns separate from...

Page 61: ...he motor may have to be tested while disconnected from the feeder cable There is no precise science to determine what size motor with what size and length feeder cable a particular surge test model ca...

Page 62: ...ber that each line high side connection point must be surge tested to the other end of its own coil and that the secondary side of the coil being surged must be shorted out jumpered together and to gr...

Page 63: ...n keys Store Store is used to record measurements to internal memory on the testers Choosing Store reveals a list of memory locations available for surge and HiPot tests Ten available Record memory lo...

Page 64: ...splay 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 Store Surge data...

Page 65: ...Cancel to return to the main menu without storing any data Up moves the cursor up the Lead list Down moves the cursor down the Lead list Press Select to choose the Lead of HiPot data type that the cur...

Page 66: ...ed record Recall record submenu options Summary Up Down Select Press SUMMARY to display the Resistance data Surge data in all three leads the Meg ohm HiPot and the PI data stored in the Record the cur...

Page 67: ...lay the recorded HiPot and Polarization Index data for the selected record Recall Surge data If the tester is currently in Surge mode the next display allows the user to choose the Lead location from...

Page 68: ...a Print Print will print the record currently on the display Clear Clear will remove or blank out the wave pattern and message area of the display It has no affect on memory locations or the data stor...

Page 69: ...command set A non inclusive list of compatible printers follows 5650 500C 550C 600C 610C 612C 695C 697C 832C 895C 970C The 895C and 970C are unique in that they have universal input power supplies an...

Page 70: ...Data Recording Retrieving 12 3 2009 71 022 V6 D30R 70...

Page 71: ...uction stators They provide a reference for associating a characteristic wave pattern with a fault type Note Variation from these wave patterns is to be expected Do not consider these wave patterns as...

Page 72: ...If all three wave pattern wave comparisons surge testing show considerable separation when testing three phase windings the motor has a Phase to Phase short Because two phases are faulty a good wave...

Page 73: ...requested information available Baker Instrument Company an SKF Group Company s Service or Applications Departments will be able to better analyze the situation and provide a appropriate response Eit...

Page 74: ...testing on coils that are assumed to be good even on brand new motors or windings Often separation is seen in all three comparisons for three phase motors but to varying degrees There may not be separ...

Page 75: ...re taped after the test which can take several hours The upside is a smaller lighter less expensive tester can be performed on a larger selection of equipment 8 Cleaning a dirty display Use a standar...

Page 76: ...t winding 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 resistanc...

Page 77: ...y of these questions were answered yes the unit is probably operational and indicates an open AC line ground connection In the case of numbers 1 through 3 above use an outlet tester to assure proper w...

Page 78: ...________________________ Phone Number ___________________ Fax ____________________ From the Name Plate on the back of the Tester Baker Product Number ___________________________ Model Number _________...

Page 79: ...utput voltage 0 30000 Volts Max output current 1000 amps Current resolution 1 10 100 amps division Over current trip settings 10 100 1000 amps Full scale voltage Current measurement accuracy 5 Meg ohm...

Page 80: ...Resolution Full scale accuracy 100 A Div Range 900 A 5 or 45 A 5 from 90 A 900 A 5 10 A Div Range 90 A 4 5 A 5 from 9 A 90 A 5 1 A Div Range 9 A 45 A 5 from 9 A 9 A 5 Voltage measurement accuracy Surg...

Page 81: ...gh Voltage DC Tests 25 31 HiPot 17 18 21 25 26 27 35 37 45 47 67 HIPOT Test 18 HIPOT TRIP WARNING LIGHT 14 HORIZONTAL POSITION 14 I IEC 20 IEEE 20 IGBT Switching Technology 42 Inductance 39 INTENSITY...

Page 82: ...2 63 64 66 67 68 77 80 Surge Test 57 SURGE HIPOT SELECTOR 15 Synchronous Motor Generator 56 T Temperature 36 Testing Assembled Motors from the Switchgear 60 Three Phase Motors 54 56 Transformers 61 62...

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