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Baker PPX40 Manual Surge Range Switch

The Baker PPX40 manual 

Surge Range 

switch for performing Surge and HiPot tests.  This switch provides positive 

control of the Surge test voltage and eliminates dependency on automatic range switching during a test. 

During HiPot testing, set this switch in the 25-40K position.  The Baker PPX does not limit the output voltage in HiPot 
mode. The Hi/Low is for Surge testing.  The LED still follows the switch, but the limit circuit is disabled.

 

Fig 9: 

Manual surge range switch on PPX40.

Table 10: 

Surge range switch positions and functions.

Switch Position

Test Voltage 
Requirements

0–25kV Surge

< 25 kV

In this position, the voltage will be limited to 25kV.

 25–40kV Surge

> 25 kV

In this position, voltage is allowed to increase above 25kV, but 
surge pulses will not be generated if the voltage is lowered 
below 25kV.

Baker Power Pack Introduction

www.megger.com 15

Summary of Contents for PPX30

Page 1: ...Baker Power Packs PPX30 PPX30A PPX40 User Guide...

Page 2: ......

Page 3: ...rights of third parties that may result from its use No license is granted by implication or otherwise under any patent rights of Megger Baker Instruments NOTICE No part of this document may be reprod...

Page 4: ...Megger is a registered trademark of Megger Group Limited All other trademarks are the property of their respective owners NOTE This equipment has been tested and found to comply with the limits for a...

Page 5: ...henomena being observed and the material properties being measured this equipment does radiate radio frequency energy while in the active test mode Directive 2011 65 EU RoHs standard Referenced Safety...

Page 6: ...Notices iv Baker Power Packs User Guide 71 061RC EN V2 www megger com...

Page 7: ...nfiguration 14 PPX40 Internal Leads Configuration 14 PPX40 Configuration for DC HiPot Tests Single Phase Test Leads 14 PPX40 Configuration for Surge Tests Single Phase Test Leads 14 Baker PPX40 Manual...

Page 8: ...Process 57 Low impedance Armature or Coil Testing Using the Baker PPX30A 61 Low impedance Armature or Coil Test Procedures for PPX30A 61 Appendix A Maintenance 67 Product Care 67 Routine Inspection 6...

Page 9: ...other contaminants Repairs and repair parts warning Replacement or repair of parts within the unit should be conducted only by Megger Baker Instruments authorized service personnel Opening a unit may...

Page 10: ...nergized For example do not adjust test leads when operating a footswitch Leads will have live voltage and severe electrical shock can result Upon completion of any Megohm dielectric absorption DA pol...

Page 11: ...high voltage circuitry The button will remain locked in position until manually retracted by rotating the Equipment Stop button clockwise Fig 1 Baker Power Pack showing Equipment Stop button Item Desc...

Page 12: ...Baker Power Pack Introduction 4 Baker Power Packs User Guide 71 061RC EN V2 www megger com...

Page 13: ...ack handle Otherwise the leads could interfere with tester measurements Make sure the analyzer s test leads are not connected together Make sure the analyzer s host ground test lead is not grounded wh...

Page 14: ...til the E STOP button has been reset 4 Power on Indicates when the AC power is turned on to the unit 5 Arc detect Indicates an arc has occurred HiPot failure The LED will flash for approximately five...

Page 15: ...ontrol Knob is turned Refer to the table below for specifications 5 Function Selector switch selects the operational function of the unit Surge HiPot 100 A Div 10 A Div 1 A Div Armature test PPX 30A o...

Page 16: ...ture a Test Select switch just below the handle so you can select the test type or test lead needed Fig 4 PPX front panel controls Baker PPX30A shown Item Description 1 Function Selector switch 2 ARM...

Page 17: ...Description 1 Test Select switch 2 Leads ground position Used to discharge device under test after completing DC tests 3 Surge test mode select from test leads 1 2 and 3 4 DC HiPot test mode 5 Do not...

Page 18: ...it ensuring that the safety strap is used to secure the unit Fig 6 PPX tester angle adjustment plate Baker PPX30A shown Item Description 1 Right wing bolt viewed from front 2 Safety strap 3 Tester adj...

Page 19: ...4 Baker PPX30 30A internal connections during Surge testing Test Select Position Test Lead 1 Orange Test Lead 2 Brown Test Lead 3 Yellow Ground Lead Black Black Braid Test Lead 1 High Voltage Ground G...

Page 20: ...ting 3 Set the Test Select switch to LEADS GROUND ground icon 4 Connect the power pack test leads to the motor leads as described in the table below Table 5 Baker PPX30 30A device under test connectio...

Page 21: ...tch 4 Set to LEADS GROUND before connecting test leads 5 Used to switch between Surge test leads 1 2 and 3 3 Set the Test Select switch to LEADS GROUND ground icon 4 Connect the power pack test leads...

Page 22: ...k Ground Black Braid Ground Motor phase A Not connected Not connected Motor frame Station earth ground PPX40 Configuration for Surge Tests Single Phase Test Leads The PPX40 does not have a Test Select...

Page 23: ...he output voltage in HiPot mode The Hi Low is for Surge testing The LED still follows the switch but the limit circuit is disabled Fig 9 Manual surge range switch on PPX40 Table 10 Surge range switch...

Page 24: ...Baker Power Pack Setup 16 Baker Power Packs User Guide 71 061RC EN V2 www megger com...

Page 25: ...5 PPX AC inlet to properly grounded AC source 1 Secure the Baker DX to the Baker PPX using the security strap located on top of the adjustment plate 2 Use the short AC power cord to connect the PPX AC...

Page 26: ...nnect them to the indicated locations on the back of the power pack as shown below Fig 11 Attaching accessories to the power pack Item Description 1 Remote E stop and safety lights connector 2 Footswi...

Page 27: ...auxiliary port AUX PP on the front of the Baker AWA IV and the end marked 30kV into the auxiliary port AUX on the front of the power pack 4 Connect the long AC power cord from the AC receptacle on th...

Page 28: ...Using Power Packs with Baker AWA Testers 20 Baker Power Packs User Guide 71 061RC EN V2 www megger com...

Page 29: ...r is connected to a power pack an inoperable condition will also affect the power pack due to loss of the surge enable signal Combining Baker AWA IV Host and Power Pack Tests To completely test a larg...

Page 30: ...checkbox 2 Enter the password for editing Test IDs Fig 13 Tests tab editing Test ID to create new Test ID 3 Click on the Add button to open the Create New Test ID dialog box as shown below Fig 14 Crea...

Page 31: ...been checked indicating that the power pack will be used for the HiPot test You should also note that you can use the Dischg Time min fields to specify a discharge interval in minutes that will stop a...

Page 32: ...ack for this test Fig 16 Surge test setup PPX30 30A 3 Click on the Close button to return to the Main window Tests tab 4 Click on the Save button to save the new test information for this Test ID The...

Page 33: ...ower Motor Using best practices all other information available on the motor s nameplate is entered into the Nameplate tab Fig 17 Creating a new Motor ID 3 After entering nameplate information click o...

Page 34: ...nection and power pack lead connection message 4 The power pack test can be aborted at this time if needed 5 Click on the Abort button to discontinue the test or click on the Continue button to procee...

Page 35: ...ngs Also ensure that the interconnect cable has been attached and is secure 12 After the test voltage is successfully reached the test timer on the Baker AWA IV s screen will start counting down 13 Co...

Page 36: ...s be held at ground potential for some time IEEE 95 recommends a grounding interval four times the amount of time the high voltage DC was applied to the windings or two hours whichever is greater For...

Page 37: ...abling the power pack output leads 20 Set the power pack s Function Selector switch to Surge Surge waveform icon Fig 23 Surge Test configuration window used during Surge testing 21 To start the Surge...

Page 38: ...ed voltage level Fig 26 Setting the voltage and waveform using the voltage output control knob 25 When you have reached the voltage level and the software completes its test a message dialog will appe...

Page 39: ...row in the Temperature Resistance Tests section 2 Click on the Temperature Enable radio button if you will be using temperature compensation 3 Click on the Resistance Enable radio button to enable the...

Page 40: ...escribed in this section apply to testing coils with normal impedance For testing low impedance devices refer to the section Low impedance Armature or Coil Testing Using the Baker PPX30A found later i...

Page 41: ...to the test leads when a test begins 5 Create a separate Test ID and a Motor ID to use during the testing process to avoid inadvertently corrupting the test history of an existing Motor ID While you t...

Page 42: ...t test on a known good coil so that you can acquire a good baseline for all coils to be tested in the lot NOTE This is not the same as using the known good coil to set a formal test reference That app...

Page 43: ...nstruct you to release the Test PTT button 19 Inspect the waveform and value for L1 in the Peak Voltage area When you are satisfied that you have a good baseline disconnect the power pack s test leads...

Page 44: ...nue to hold down the Test PTT button until instructed to release it Fig 32 Running Surge test on subsequent coils Lead 2 25 After the software completes its processing it will instruct you to release...

Page 45: ...e Zero Start function and allows the unit to immediately apply the full target voltage level to the test leads With the key in the vertical position testing starts at zero volts and must be ramped up...

Page 46: ...s enabling single phase testing have been set up in the Temperature Resistance Test setup window as described earlier in this chapter but leave the tests set to OFF while completing the Test ID setup...

Page 47: ...ition the waveform for optimal viewing Fig 36 Ramping voltage to acquire Lead 1 waveform 30 The software will alert you to release the power pack s Test PTT button button or footswitch when your wavef...

Page 48: ...eference acquired 42 To continue testing additional coils disconnect the current coil used to acquire the reference and set it aside CAUTION Ensure that the Leads Energized light on the power pack tur...

Page 49: ...both leads for a coil you can close the Surge Test window and save the test data collected 49 Disconnect the coil from the tester NOTE The software also provides features to save up to three waveforms...

Page 50: ...on Selector switch 2 Armature test mode Low impedance device testing such as armatures DC field coils and interpoles Employs the Baker ZTX impedance matching transformer circuitry built into the PPX30...

Page 51: ...test fixture to the PPX30A power pack Item Description 1 PPX30A Armature Surge connector 2 PPX30A Armature Sense connector 3 Footswitch connector connect to Footswitch connector on back on PPX 4 ATF 5...

Page 52: ...st 3 Turn the PPX30A Zero start Override key switch to the horizontal position to enable zero start override WARNING When the zero start override feature is enabled target test voltage levels will be...

Page 53: ...X30A power pack appear within the Surge Test and Armature Test setup windows 1 With the proper Motor ID selected click on the Tests tab 2 Ensure that the correct Test ID for the device appears in the...

Page 54: ...device For this example we use 600 volts 7 Check the Enable PP box and the box labeled Arm Fig 43 Setting up Surge Test window for Armature testing using the power pack Using Power Packs with Baker A...

Page 55: ...Target Voltage is set as needed for your armature 11 Set the Volts Div value to Auto The analyzer will auto range for the reference waveform Fig 44 Surge Test Armature window 12 Change the reference t...

Page 56: ...configuration button at the end of the Surge Test row to open the Surge Test setup window Because this is a manual test it is run from the Surge Test Armature window 4 The armature operator will posi...

Page 57: ...d and an inset bar graph will be displayed depicting the EAR percentage versus the reference bar s waveform If the bar failed the EAR bar on the graph will be red 13 Up to three additional waveforms c...

Page 58: ...low 18 Because this is not an automatic test you must click on the yellow Save Results button to save the test results to the database so it can be recalled for further viewing and to print reports Fi...

Page 59: ...ing the test and can be at the same voltage potential as the winding Take all precautions to avoid touching these leads to prevent injury or death from electrical shock After completing high voltage t...

Page 60: ...disconnect the Baker DX tester leads and set them safely aside 3 Connect the power pack s test leads as described in the Power Pack Configuration for DC HiPot Tests for the power pack you will be usin...

Page 61: ...monitoring the leakage current for example if the signal is 50 A switch to 10 A division 5 A switch to 1 A division Typically the leakage current should rise initially then fall and remain at a consta...

Page 62: ...hm PI testing and DC HiPot Step testing will create two separate records 9 Turn the power pack s Voltage Output Control knob clockwise to increase the voltage level and counterclockwise to decrease 10...

Page 63: ...st suite release the Test PTT button or footswitch WARNING To prevent injury or death from electrical shock always allow sufficient time for the test winding to completely discharge before disconnecti...

Page 64: ...Megohm PI to Step test and HiPot are included in one record This can only be achieved when using the Baker PPX to conduct all tests The Test PTT button or footswitch is held down during the entire tes...

Page 65: ...del being used and the test type being conducted Surge Test Example Process 1 Ensure the test leads are properly connected for the motor phase that you are testing 2 Touch the Surge icon from the DX s...

Page 66: ...st by pressing and holding the power pack Test PTT button or footswitch Using the power pack s Voltage Output Control knob increase the voltage A waveform should appear immediately NOTE Be sure to inc...

Page 67: ...DX screen release the Test PTT button or footswitch 16 Press the Lead 2 icon then repeat the process to test phase 2 17 Press the Lead 3 icon then repeat the process to test phase 3 Fig 55 Power pack...

Page 68: ...ow sufficient time for the test winding to completely discharge before disconnecting the test leads On the Baker PPX30 30A set the Test Select switch to the LEADS GROUND position before disconnecting...

Page 69: ...N To avoid damaging the unit under test or substantially reducing the switching element s useful life do not change the Function Selector switch out of the Armature position during the performance of...

Page 70: ...e Coil mode icon then touch the Arm Bar icon DC IP icon for single coil testing 8 The test start screen should look similar to the example shown below Fig 58 Armature bar test start screen for Baker P...

Page 71: ...he waveform stable and a minimum of five pulses applied release the Test PTT button or footswitch or fixture Test button NOTE When testing armatures apply the surge pulse until you see the EAR graph a...

Page 72: ...then the All Waveforms icon in the submenu Fig 60 Selecting waveforms to view all waveforms 17 The waveform display changes similarly to the example shown below All waveforms collected to this point w...

Page 73: ...in the example below Fig 62 Armature test report screen simple example In the simple example above the EAR percentage for armature coil 12 is higher than most but still within tolerance however armatu...

Page 74: ...66 Baker Power Packs User Guide 71 061RC EN V2 www megger com...

Page 75: ...s Care of the Instrument The instrument should always be handled with care and not dropped Always make sure that the instrument is secured when being transported to prevent mechanical shock Test Leads...

Page 76: ...ift points on the rear or the unit secured to a reinforced metal chassis specifically designed to allowed top side lifting The front handle of the power pack is also attached to a reinforced metal cha...

Page 77: ...ase note the options used Any information concerning the instrument is helpful Equipment Return Before returning any equipment or components to Megger Baker Instruments the following steps should be t...

Page 78: ...70 Baker Power Packs User Guide 71 061RC EN V2 www megger com...

Page 79: ...has a recommended standard see table for test voltages for DC tests and Surge tests conducted on a motor generator or transformer That standard is twice the AC line voltage plus 1 000 volts This test...

Page 80: ...11 890 8 917 6 900 5 634 19 719 14 789 13 800 11 268 39 438 29 578 Table 24 IEC 34 15 V Line Per Unit V Line 4E 5 000 0 2 us 65 480 392 6 920 4 498 575 469 7 300 4 745 600 490 7 400 4 810 2 300 1 878...

Page 81: ...PPX30A Weight 310 lbs 141 kg 290 lbs 132 kg 321 lbs 146 kg Dimensions 24 x 48 x 33 in 610 x 1219 x 838 mm 24 x 48 x 33 in 610 x 1219 x 838 mm 24 x 48 x 33 in 610 x 1219 x 838 mm Power requirements 100...

Page 82: ...74 Baker Power Packs User Guide 71 061RC EN V2 www megger com...

Page 83: ...itch 20 005 RLC adapter for resistance testing 81 ATF 002RC Surge and Sense Cable adapter connects between PPX30A Surge and Sense connectors on rear of power pack and ATF 5000 cable Surge and Sense co...

Page 84: ...r USA Dallas 4271 Bronze Way Dallas TX 75237 1019 USA T 800 723 2861 USA only T 1 214 333 3201 F 1 214 331 7399 E USsales megger com Megger AB Rinkebyv gen 19 Box 724 SE 182 17 DANDERYD T 08 510 195 0...

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