SKF Baker AWA-IV 12 HO Page 210 User Manual Download

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PUB CM/I4 71-015 EN V13.2 Static Motor Analyzer—Baker AWA-IV User Manual

Index

Opening an existing database 13, 29

Operating and shipping positions 10

Operating position 118

Overcurrent trip test 152

Performing an example test 81

PI 74

Polarization Index Test Results table—

(TestResultsPI) 167

Pollution degree II 8

Power pack lifting and shipping 9

Power pack setup 118

Power requirements 8

Precautions for proper operation 149

Predictive maintenance 107

Principles of armature insulation testing 133

Printing reports 98, 144

Proper storage of leads/unit 152

Quality control 108

Ramp voltage test 61

Recommended testing sequence 77

Recommended test voltages for HiPot and Surge

tests 80

Recommended test voltages for insulation

resistance testing 80

Reference Surge waveform table—

(RefSrgWaveForm) 180

Relative humidity 75

Renaming a route 39

Repair parts 147

Resistance failure types 183

Resistance leads 24

Resistance measurements 59

Resistance Trending Graphs 72

Restoring a database 20

Reviewing test results/data 95, 142

Route tab 39

Running an automatic test 91

Running the combined Baker AWA-IV and power

pack tests 122

Running the manual surge test using the Baker

ZTX 139

Safety and general operating information 3

Safety precautions 4

Selecting an optimal environment 25

Self-help and diagnostics 147

Service: What to do first 150

Setting up power packs 118

Setting up the Baker AWA-IV tester 25

Software fault messages 183

Special features of the Baker AWAIV 107

Special software trending features 75

Starting the software , 12

Step voltage test 79

Step Voltage test 62

Summary of Contents for Baker AWA-IV 12 HO

Page 1: ...SKF Static Motor Analyzer Baker AWA IV User manual...

Page 2: ......

Page 3: ...toring electric motor testing index html Technical asistance See our website at www skf com cm tsg for technical assistance authorized service center information Service department phone number 1 858...

Page 4: ...ion furnished in this manual by SKF USA Inc is believed to be accurate and reliable However SKF USA Inc assumes no responsibility for the use of such information or for any infringements of patents or...

Page 5: ...ximation of the laws related to Member States relating to the electromagnetic compatibility as amended by Council Directive 93 68 EEC Note due to the phenomena being observed and the material properti...

Page 6: ...pyright trademark patent or trade secrets laws of the United States or any other nation including all rights associated with the protection of computer programs and or source code 1d Person The term P...

Page 7: ...rly in the applicable purchase order or other ordering documents memorializing your license acquisition provided however that all network clients workstations are connected to a single licensed databa...

Page 8: ...see may install one or more additional copies of the Software as specified in the license corresponding to the specified sales order Except for the limited reproduction rights set forth in this paragr...

Page 9: ...of Licensor s Intellectual Property Rights and acknowledges that Licensor s Intellectual Property Rights related to the Software are valid and enforceable 2j Material Terms and Conditions Licensee spe...

Page 10: ...employee of Licensee without the prior written consent of Licensor 7 LIMITED WARRANTIES 7a Licensor warrants that the Software will perform substantially in accordance with its documentation for a pe...

Page 11: ...at the same form an essential basis of the bargain between the Parties 9 TERM AND TERMINATION 9a Term This Agreement shall commence on the Effective Date and shall continue in existence until it is te...

Page 12: ...N In the event that either party initiates litigation relating to or arising out of this Agreement Licensor and Licensee irrevocably submit to the exclusive jurisdiction of the state or federal court...

Page 13: ...n the Parties which supersedes and merges all prior proposals understandings and all other agreements oral or written between the Parties relating to the use of the Software 18b Amendment This Agreeme...

Page 14: ...olation of Sections 2 4 6 10 15 and 17 of this Agreement and that monetary damages in such event would be substantial and inadequate to compensate Licensor Consequently Licensor shall be entitled to s...

Page 15: ...nce authorized service centers 8 Unpacking the unit 8 Pollution degree II 8 Power requirements 8 Environmental conditions 9 Power pack lifting and shipping 9 Lifting the instrument 9 Operating and shi...

Page 16: ...g the analyzer 25 Connecting test leads to motor under test 26 Configuring a printer 26 Using the footswitch 26 5 Baker AWA IV software overview 27 Starting the software 27 Creating a new database 28...

Page 17: ...results 70 Using the Trending tab 71 Max Delta R 72 Resistance Trending Graphs 72 Insulation Resistance MegOhm 73 PI 74 HiPot 74 Relative humidity 75 Special software trending features 75 6 Test proc...

Page 18: ...IV 2 kV and Baker AWA IV 4 kV 109 Using the Hi L technique 110 Fine tuning the technique 111 8 Using power packs with 6 12 kV models 117 Power pack setup 118 Operating position 118 Combining Baker AWA...

Page 19: ...Service What to do first 150 Open condition display 150 HiPot display checks 150 Open ground check 151 Answer these questions 151 Limited output surge waveform 151 Proper storage of leads unit 152 Che...

Page 20: ...d 175 Step Voltage test ID table TestIdPrgHiPot 179 Reference Surge waveform table RefSrgWaveForm 180 Database Information table DatabaseInfo 181 Work list table Route 181 Motor voltage class table Mo...

Page 21: ...n is set in the following format and structure NOTE Indicates additional information about the related topic that deserves closer attention or provides a tip for using the product NOTICE Indicates inf...

Page 22: ...2 PUB CM I4 71 015 EN V13 2 Static Motor Analyzer Baker AWA IV User Manual About this manual...

Page 23: ...erminal Located on rear panel of instrument by ground terminal Warning about hazardous voltage and risk of injury or death from severe electrical shock Located beside each red test lead on front panel...

Page 24: ...all conditions at all times Always know what test is being performed and when For example do not adjust test leads when operating a footswitch Leads will have live voltage and severe electrical shock...

Page 25: ...You must replace defective damaged or broken test leads with factory authorized parts to ensure safe operation and maintain performance specifications Ground the product The devices covered in this ma...

Page 26: ...y discontinue a test and to shut off power to the power pack s high voltage circuitry The button will remain locked in position until manually retracted by rotating the Emergency Stop button clockwise...

Page 27: ...t and it is in the line with the status lights on the remote E Stop accessory Figure 4 Baker ZTX unit and Remote E Stop Emergency Stop buttons After being pressed the button will remain locked in posi...

Page 28: ...ctive 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 p...

Page 29: ...g straps placed under the unit as shown in the photos below Do not use the handle of the instrument to lift the unit Example of strap use only shown in the image below Always remove and secure tester...

Page 30: ...ly with all four wheels down on a level service If the product must be shipped for any reason the package containing the power pack must be properly labeled with this side up labels to ensure the inst...

Page 31: ...plants each in a remote location Each plant has nearly 1000 motors that need periodic testing All works well for several months until a motor that was previously tested fails The maintenance manager...

Page 32: ...new database 1 Click on the Create a New Database radio button in the opening window Type the name of the database and click Save 2 If the software is already running you can create a new database by...

Page 33: ...e 1 Click on the Open an existing database radio button upon entering the software 2 To open a database after the software is running click on the Open option under the File menu 3 Alternatively click...

Page 34: ...ase for each building in a given site A larger organization might require that data is kept in a centrally located database on a network and have local databases on each analyzer which then update the...

Page 35: ...ctionality Transferring motor and test results data Two databases need to be open to transfer motor information test results data and Test IDs a source database and a destination database Both databas...

Page 36: ...r the file name Pick the default database or choose another database to transfer data from as needed Figure 11 Select source Baker AWA IV database 4 After selecting the source database click the Open...

Page 37: ...k on the Add All button 11 The Transfer List displays all motors that will be transferred when you click the Transfer button If the Transfer List includes motors that do not need to be transferred rem...

Page 38: ...button Transferring Test IDs Test IDs can be transferred separately from Motor IDs To transfer Test IDs you will follow essentially the same process described in the Transferring motor and test result...

Page 39: ...d up network drive Figure 15 Archive The archive feature provides an easy means to back up Baker AWA IV data The feature is also the best way to move a database to another storage device or computer I...

Page 40: ...hived file bak Click on the OK button to finish the archive process Restoring a database NOTE In the past archives were created for storage devices with lower capacity so compression was used to minim...

Page 41: ...ase to restore choose the folder to which the archived database will be extracted If the database is to be restored to a different folder relocate to that folder When the appropriate folder is located...

Page 42: ...not be overwritten If the archived database is still needed rename the existing database through Windows Explorer then restore again or restore using another folder that does not contain the same name...

Page 43: ...apacity is identified by the markings found just below the touch screen Figure 22 Front panel controls for AWA IV 2 kV and 4 kV models VGA port The VGA port is used to connect the tester to a larger m...

Page 44: ...TX and DC testing You must keep the leads clean and dry for best measurement performance Voltage output control knob 6 kV and 12 kV models only Turn the knob clockwise to increase the applied voltage...

Page 45: ...or dust Making basic connections and starting the analyzer 1 Place the Baker AWA IV on a large table or bench Check the power switch and ensure it is in the Off position 2 Plug one end of the power c...

Page 46: ...er reads back to the tester For this reason it is important to ensure that both parts of the lead clips are seated well when testing CAUTION Ensure that you understand how leads should be connected fo...

Page 47: ...Test ID consists of all test parameters to be used when performing tests on a motor Details such as test voltages pass or fail criteria and test times are contained in a Test ID You name and define Te...

Page 48: ...clicking on New from the File menu or the new database icon on the toolbar 3 Whichever method you choose the same Create New Database window will appear Figure 25 Creating a new database 4 The Save a...

Page 49: ...the Open option under the File menu or click on the open database icon in the toolbar 2 A Select Baker AWA IV Database window appears to help you locate and select the desired database It will defaul...

Page 50: ...e analyzer information is usually entered at the manufacturer before the Baker AWA IV is shipped however it may be changed via calibration which can be invoked by checking the Enable Calibration box i...

Page 51: ...abase The Baker AWA IV software Main window is split into two panes The left pane contains three different tabs Explore Motor ID and Route that facilitate browsing through the motors in the database T...

Page 52: ...gories implied by the menu labels Each menu is described in the following sections File menu Clicking on the File menu drops down a list of items that help you choose the database s that you want to u...

Page 53: ...setting that requires the use of voltage classes When this feature is enabled a check appears next to the item When voltage classes are enabled you will be required to have a voltage class assigned t...

Page 54: ...rrent location of the database file you are currently using Clicking on Load Text File opens a window to help you select a text file to view within the system Figure 32 Database menu Window menu The W...

Page 55: ...eports and other offline applications The system uses standard hotkeys for capturing screens and includes MS Paint for processing and modifying captures as needed Scroll down to the tool tray to open...

Page 56: ...Motors and About Hovering the mouse cursor over an icon provides you with flyout tool tips that identify the icon The Toolbar also identifies the current motor displayed in the user interface along wi...

Page 57: ...help you locate and select a particular Motor ID The two upper levels of the tree correspond to the location and building in which the physical motor is housed Figure 37 Explore tab Location and Buil...

Page 58: ...he Motor ID needed into the field found just above the list The list will automatically scroll to the nearest Motor ID that begins with those characters and will automatically update as you enter more...

Page 59: ...te ID After entering the new ID start adding Motor IDs from the Available Motors list on the right to the Route Motors list on the left 2 To add a motor select the Motor ID on the right and click on t...

Page 60: ...Ds that you want to add from the Available Motors list then click on the Add button Select one motor at a time or use the control shift keys to select a group of Motor IDs 5 To remove unwanted Motor I...

Page 61: ...ferent elements can be displayed in defined formats within the Motor ID tab as well depending on how the parameter settings are defined Figure 40 Right pane of Main window features Data Tests and Tren...

Page 62: ...sults data for a variety of tests confirm whether a test has been selected to run configure or execute tests and display trending graphs that chart acquired data over time Figure 41 Right pane of Main...

Page 63: ...test By clicking on a date time you can view test result data for that specific date within the Application Surge PI or Step Ramp Voltage tabs in the lower section The view in the lower section chang...

Page 64: ...abels 1 and 2 Additionally a custom string field can be added by assigning a label name to provide supporting information about the motor This information is not related to the location or the general...

Page 65: ...Oper operating voltage field is also required Ensure that the proper Winding Config radio button is selected for your motor This parameter is used elsewhere in the system All other fields in the Namep...

Page 66: ...o be used when testing the new motor Refer to Creating a Test ID for more information on this topic if needed NOTE Clicking the Reset button will re display the previous motor and nothing will be adde...

Page 67: ...r before it was tested and so on Figure 46 Data tab Applications view NOTE The tester type tester serial number and calibration date are stamped on this record to indicate what tester performed the te...

Page 68: ...ry of parameters used for a specific test as it was executed by the operator during testing In many cases it will simply reflect the parameters assigned to the Test ID however if an operator makes cha...

Page 69: ...e green If one or more tests fail the background will be red If no tests were performed the cell background will be gray Use the scroll bars to the right and bottom to scroll through the results for e...

Page 70: ...ys as the next examples illustrate In a comparison view all waveforms for all leads can be superimposed on each other You can select each lead for display if needed Figure 50 Enlarged Surge view all w...

Page 71: ...he tolerance used during the test The P P EAR evaluates each pulse of the Surge test to identify weakness in turn insulation This test should be used whether the rotor is installed or not threshold is...

Page 72: ...tage DA PI ratios and four check boxes Use the Megohm Plot and Current Plot check boxes to select whether the data will be plotted in minutes or seconds Unchecking both boxes in a section removes the...

Page 73: ...ermines what will be plotted on the graph and in the table Voltage is displayed in blue and real time current in red The green line with triangle markers indicate the current at the end of each step F...

Page 74: ...rrent and the MegOhm value at each end point Figure 55 Step Ramp Voltage view showing current vs time In the graphic displays you can hold down the left mouse button and drag a box around an area of t...

Page 75: ...To run an automatic test click the Run Auto Test button Each test that is turned on will be performed in the sequence as it appears in the Tests tab view To edit Test IDs click on the Edit Test ID ch...

Page 76: ...elow The temperature entry and resistance test can be turned on or off using the enable radio buttons on the left side of the window Figure 57 Temperature Resistance test window The temperature entry...

Page 77: ...er entered in the corresponding field the motor will fail the resistance test The acquired resistance values may be temperature corrected by checking the Correct to box and defining the related parame...

Page 78: ...other two leads held at ground A balance test can be done or the low voltage leads can be used for a more precise test A resistance value that is manually entered will be different a measurement made...

Page 79: ...measurement will be of coils 1 4 in parallel with the series combination of coils 2 5 and 3 6 The lead 2 measurement should be from terminals 2 4 and terminals 3 5 Likewise the lead 3 measurement sho...

Page 80: ...subtleties these two options let you set up the tests so that no unnecessary time is spent on the PI test Each test can be run individually by clicking the appropriate Run Test button Alternatively al...

Page 81: ...current If it remains linear with the voltage the winding is in good condition If the current wavers up and down the winding might be contaminated The figure below provides a graphical representation...

Page 82: ...he steps are appropriate for the application being tested The second window is used to enter up to 30 voltage steps or test intervals for each step This window will also appear when the Step Voltage t...

Page 83: ...ault but you can manually enter a specific value if you prefer This field determines the y axis scale on the surge waveform graph The Second Div x axis field is also set to Auto by default to capture...

Page 84: ...0 or 1 and the denominator is the highest P P EAR recorded over the entire test Check the Test Ref EAR box to enable setting pass fail criteria when comparing the surge waveforms from the test to a p...

Page 85: ...rise as the energy is increased by the analyzer to create the displayed waveform Figure 68 Surge waveform window Effectively the energy bar graph shows how far down the pedal must be pressed to obtai...

Page 86: ...setup window opens set the desired voltage Zero Crossing and both L L EAR and P P EAR tolerances 4 The Volts div and Seconds Div parameters default to auto however if you know these settings enter the...

Page 87: ...n the toolbar is the reference Motor ID 2 If you want to ensure that the motor passes all tests click the Run Auto Test button then resume the Surge Test reference waveform process when you get to the...

Page 88: ...he Use as Reference dialog box 6 Motors that use the Test ID associated with the reference motor s Test ID will now have Test Ref EAR enabled in the Surge test setup window 7 When you have finished th...

Page 89: ...rn to the Main window Tests tab 5 Click the Run Auto Test button to begin the test 6 The software will automatically run through the resistance and DC tests and if the motor passes all other tests it...

Page 90: ...the overlaid reference motor s surge waveforms dashed lines Figure 74 Surge results display NOTE If the reference waveform is very close to the selected motor s waveform it will hide the dashed wavef...

Page 91: ...long term status of a motor s insulation These graphs can be reset are selectable by date and have several printing options You can hold down the left mouse button and drag a box around an area of th...

Page 92: ...ce line to line and coil Selecting one will bring up a graph similar to the one shown in the example Resistance measurements are taken against time and show very little variation over the test interva...

Page 93: ...gOhm trending graph NOTE When trending MegOhm values the temperature corrected values should be used and not the uncorrected values Both values are available in the software However sometimes it is no...

Page 94: ...graphs Figure 79 PI trending graph HiPot Clicking on HiPot in the dropdown box brings up a graph of the HiPot leakage current data This has the same features as the MegOhm trending graph Figure 80 Hi...

Page 95: ...isplayed Hold the left mouse button then drag and draw a box around the points you want to display When you release the left mouse button the graph will automatically re scale and display the points i...

Page 96: ...ove an unwanted record from the selection Figure 82 Dates to trend spreadsheet Additionally all of the records on this window can be exported to a comma separated values CSV file for later importing i...

Page 97: ...ore rigorous tests accepting the idea that if a test fails troubleshooting and repair should begin at that time More rigorous testing should only commence after satisfactory diagnosis and or repair CA...

Page 98: ...contaminants Connections to the actual coils might be damaged The wrong insulation might have been used to connect the coils to the motor s junction box No further testing is necessary until the reas...

Page 99: ...ason for an unacceptable HiPot reading is found and corrected Step Voltage test The Step Voltage test is used for predictive maintenance and field testing This DC test is performed at a voltage level...

Page 100: ...d Surge testing a motor generator or transformer are twice the AC line voltage plus 1000 volts 2 x AC line voltage 1000 volts test voltage This test voltage is consistent with NEMA MG 1 IEEE 95 1977 f...

Page 101: ...n add it as well 4 If you are creating a Motor ID for a motor that does not have a similar motor already in the system select a Motor ID with the same operating voltage just to start the process then...

Page 102: ...utton to add the new Motor ID to the database 10 After the Save button is clicked the Select Test ID dialog box appears Figure 84 Test ID 11 Assign a Test ID to the newly created motor In this example...

Page 103: ...xample we will add a new Test ID 2 From the Tests tab check the Edit Test ID box 3 Enter the password in the dialog box that appears NOTE If this is the first time you edit a Test ID on the analyzer y...

Page 104: ...that will include DA and Step Voltage tests Figure 86 Test ID input 7 Using the dropdown list select a Target Motor Voltage Class For this example choose the existing voltage class of 480 If it does...

Page 105: ...Resistance test configuration buttons by default they are labeled Manual or 3 Lead High V The Temperature Resistance Test setup window will appear next 2 Because the Temperature entry step has been s...

Page 106: ...e low voltage leads so there is no Res Leads box to check 7 Check the Delta R box and ensure it is set to 10 If the spread of resistance readings are more than 10 the motor will fail 8 Because tempera...

Page 107: ...as a DA test by checking the DA Only box as shown in the example below Doing a full PI test would not likely yield useful information Figure 89 DCTest parameters MegOhm and DA parameters set If you cl...

Page 108: ...the parameters needed close the Config Wizard to return to the DCTest setup window 7 In the example above we see that parameters are set for the Step Voltage test 8 Click on the Temp Correction dropd...

Page 109: ...R Line to Line EAR is turned off because this motor will be tested with the rotor installed If this option is selected a nuisance trip could occur because the rotor coupling is different for each phas...

Page 110: ...ree phase test but on three independent windings the feature provides the time needed to complete the reconfiguration 11 Other features in the Surge setup window apply to special cases that are docume...

Page 111: ...ests tab to get to the main testing window If the Motor ID setup and the Test ID setup procedures were properly completed the analyzer should be at the correct place to begin the automatic test for th...

Page 112: ...e Temperature Resistance Test setup window will close If low voltage leads were used a dialog box appears to instruct you to switch to the high voltage leads MegOhm Starts by ramping up all test leads...

Page 113: ...eset by the example Test ID the voltage is ramped up to 2000 volts in 500 volt steps and held for 60 seconds at each step If the analyzer detects a low MegOhm reading or a overcurrent trip testing wil...

Page 114: ...t any point a dialog box appears offering options to test the next lead or to discontinue testing Figure 96 Surge Test setup window appears when Surge test is executed If no failures occur the data fr...

Page 115: ...the bottom Figure 98 Main window Data tab Results Summary view Figure 99 Date time results summary section close up The Date Time area shows a quick summary of the time and date of tests and whether t...

Page 116: ...e the desired column width Figure 100 Date time results summary section close up The Results Summary view presents the test data acquired in a spreadsheet style The test date and time are shown across...

Page 117: ...ge DA ratio and PI ratio are displayed on the right side Because this test was a DA only the PI ratio has I 0 No PI indicating there is no PI value because the current was zero Figure 102 Reviewing PI...

Page 118: ...gure 104 Report generator Start the Report Generator by Clicking on File then Print Holding down the Ctrl key on your keyboard and pressing the P key Clicking on the printer icon in the upper left sec...

Page 119: ...n the Output Report To dropdown list to select the report format needed Your options include RTF Rich Text Format MHTML web archive MS Word if installed Printer Comma Delimited Text File and Ref to Ba...

Page 120: ...inter is selected as the output 4 When the Create Report button is clicked the Report Generator will go through the entire database looking for failed tests that occurred on 3 17 2017 5 When the softw...

Page 121: ...h discretion because printing reports to MS Word takes time selecting a lot of records to print means the system would be tied up until all records can be transferred to the Word document A example Wo...

Page 122: ...Figure 109 Example MS Word Report with nested surge results and graphics Files can be saved in other formats including MHTML MIME HMTL web archive a comma delimited text file and Ref to Bar EAR CSV f...

Page 123: ...nter the value for the new motor class needed In the following example we created a 230 Volt class 6 You do not need to enter anything in the Enter new Test ID field but you can do so if you plan to c...

Page 124: ...will slowly migrate to the left as the voltage is increased If the voltage is increased at too fast a rate the movement can cause the P P EAR to generate a value greater than 10 causing the tester to...

Page 125: ...fted Otherwise the capacitors will absorb the surge pulse preventing it from entering the coils and negating the diagnostic value of the test Figure 111 Removing capacitors from motor circuit to preve...

Page 126: ...106 PUB CM I4 71 015 EN V13 2 Static Motor Analyzer Baker AWA IV User Manual Test procedures...

Page 127: ...mmed and used properly and tests are conducted precisely trending can help monitor the rate of insulation decay Observing data over time can also help establish a schedule for motor testing During mai...

Page 128: ...se reasons for failure and it can provide data to help you make sound decisions about refurbishment vs replacement Isolating the site of a phase to phase short for example can be done by performing a...

Page 129: ...og to digital converter and the memory size assigned to it The maximum sample time of both models is approximately 2 milli seconds This illustrates the transient nature of the surge pulse it is applie...

Page 130: ...uence is to program two Test IDs each being selected once during the DC motor testing sequence Test ID 1 Armature Armatures can be low inductance and very low resistance They can also be vulnerable to...

Page 131: ...ds and A1 A2 armature leads For this Motor ID we created two separate Test IDs using the tests described The Tests tab for the shunt fields Test ID could look like the following example Figure 113 Tes...

Page 132: ...ush carbon contamination Expect DC resistance of the fields F1 F2 to be much greater than the armature Expect the ability to employ the Hi L technique on the shunt fields Employ target corrected resis...

Page 133: ...nce if you plan to use trending later 2 DC resistance of the armature is likely quite low A1 A2 so click on the Resistance Enable radio button to ensure an accurate repeatable measurement 3 Ensure tha...

Page 134: ...t fields Test ID employ the hard coded time base and the Hi L technique The following illustrations show the steps to program the time base specifically for the shunt fields 7 Set micro seconds to 200...

Page 135: ...is not selected 10 Click Close then click Save to commit the changes for the Test ID Uncheck the Edit Test ID box Figure 117 Surge test settings for armature Test ID Hi L not selected PUB CM I4 71 015...

Page 136: ...d to ensure that the two Test IDs created for the motor are selected and run in turn An alternative is to create separate Motor IDs with similar names perhaps adding Armature and Field to the end of e...

Page 137: ...looped on the power pack handle The power pack surge signal can be sensed by the Baker AWA IV which will result in interference with its computer Ensure that analyzer and power pack leads are always s...

Page 138: ...AC power source NOTE The Baker AWA IV is equipped with a ground fault monitor and indicator This circuitry should not hinder operation of GFI protected AC power circuits 4 Power up the Baker AWA IV a...

Page 139: ...s by itself so the power pack will have to be used Briefly the procedure will be to Create a new Motor ID Create a new Test ID Set up the Test ID for the test voltages above Perform the tests with the...

Page 140: ...10 Click OK to continue 11 In the Tests tab turn on the Resistance MegOhm PI HiPot and Surge tests 12 Open each test setup window to properly configure the tests The DCTests setup window is shown in t...

Page 141: ...n be high enough to present a shock hazard to personnel The Surge Test setup window is shown below In this example the Surge Voltage has been set to 14200V and the Enable PP power pack box has been ch...

Page 142: ...message 4 The power pack test can be aborted at this time Ensure that the test area is safe and the motor leads have been properly connected before continuing 5 Click on the Abort button to discontinu...

Page 143: ...ted to release the button Figure 125 Test leads discharging message dialog CAUTION Due to the polarization of the insulation in high voltage motors a dangerous situation can develop if the motor is no...

Page 144: ...time The labels on this knob are 1 test lead 1 2 3 HiPot and Leads Ground Figure 126 Power pack Test Select and Function selector switches Using the three phase test leads you only need to make one c...

Page 145: ...ge and HiPot testing Red Test Lead 1 Red Test Lead 2 Red Test Lead 3 Black Ground Lead Black Braided Cable Motor phase A Motor phase B Motor phase C Motor frame Motor frame or station ground Table 4 I...

Page 146: ...n in the test setup window 17 If test results should be saved click on the yellow Save Results button in the Main window Tests tab CAUTION Always allow sufficient time for the test winding to complete...

Page 147: ...5 Adjust the voltage required so that surge voltage is at least 5000 volts 6 Enable the power pack by checking the Enable PP box An error message will appear if a voltage below the minimum for the pow...

Page 148: ...lick on the Lead 1 button in the Run Surge section of the Surge Test setup window If you attempt to start by using the power pack s push to test button you will see a message instructing you to use th...

Page 149: ...instructing you to release the Test button 16 Click on Lead 2 then Lead 3 in the Run Surge section to test each of those phases in turn using the process just described The software will lead you thro...

Page 150: ...nnected Open not connected Motor frame Motor frame or station ground 7 Turn the Output Control knob on the power pack to MIN full counterclockwise 8 Select one of the HiPot settings using the power pa...

Page 151: ...Motor phase A Motor frame 10 Connect the safety ground the smaller diameter black ground lead to the frame of the test winding and not to the coil ground lead Results of the surge test will be erroneo...

Page 152: ...sconnecting the test leads The recommended practice is to discharge the winding for duration of at least four times the duration of the DC HiPot test for high voltage windings 132 PUB CM I4 71 015 EN...

Page 153: ...lation is evaluated using the surge test The ground wall insulation includes the insulation isolating the commutator bars from ground along with the insulation isolating the copper turns in the rotor...

Page 154: ...cable between AWA and ZTX 2 Connect Baker AWA IV test lead 1 to the TEST LEAD 1 receptacle located on the back of the Baker ZTX 3 Connect Baker AWA IV test lead 2 and 3 and the ground lead to the GND...

Page 155: ...cts should be centered within each bar Figure 134 ATF 5000 bar to bar armature test accessory NOTE Refer to the ATF 5000 User Manual for more information on using and maintaining the accessory Other a...

Page 156: ...ith ARM or armature attached for easier distinction 3 Ensure that the new armature Motor ID is selected then create a new Test ID to specifically test armatures For example create a new test ID called...

Page 157: ...s shown in the example below Figure 136 Enable Baker ZTX by checking Arm box 9 Immediately after you check the Arm box the Surge Test setup window will automatically change to the Surge Test Armature...

Page 158: ...Limit as needed the default is set to 10 13 Click on the Close button to return to the Main window Tests tab 14 Click the Save button to save the Test ID 15 Click the Edit Test ID check box to turn o...

Page 159: ...AT101ZTX 3 Click on the test configuration button at the end of the Surge row to open the Surge Test setup window Because this is a manual test it is run from the setup window 4 The AWA operator must...

Page 160: ...n or footswitch The analyzer will energize Lead 1 at the preset voltage and the waveform will be displayed on the screen as the red wave The reference is also displayed as the blue waveform A referenc...

Page 161: ...be tested 17 If at any time before you save the full test results you want to retest a bar you can enter that bar number directly into the Bar Control field or use the up and down arrows to navigate t...

Page 162: ...he Surge view will also display the saved bars number peak voltage and reference to bar EAR 3 Click on the Enlarge button for a larger version of the surge graph 4 Click on the EAR Graph button for a...

Page 163: ...to draw a box around the bars you want to enlarge When you release the left mouse button the graph will automatically rescale and display the bars inside of the box you drew 6 To reset the graph click...

Page 164: ...Click on the Create Report button A report similar to the example below is generated The report generator determines which test results are collected via the normal surge testing process and which are...

Page 165: ...ain window 2 Select the desired filter options 3 Using the Output Report To dropdown list select Ref to Bar EAR CSV file Figure 144 Setting Output Report To Ref to Bar EAR CSV 4 Click on the Print Tex...

Page 166: ...146 PUB CM I4 71 015 EN V13 2 Static Motor Analyzer Baker AWA IV User Manual Using the Baker ZTX with Baker AWA IV analyzers...

Page 167: ...when performing repairs Ensure that all precautions are taekn to avoid injury or death from severe electrical shock During repairs do not substitute any parts Use only factory supplied parts to minimi...

Page 168: ...Applications Common application problems There are a few common application related problems Please review the following cases 1 The Baker AWA IV will not give the desired output test voltage for the...

Page 169: ...gh in resistance 3 2A broken test lead may be the cause Under heavy use test leads should be checked weekly to ensure that there is no breakage Grasp the boot and clip in one hand while pulling on the...

Page 170: ...analyzer are good check the connections and continuity of the test winding HiPot display checks 1 The HiPot display shows only the voltage or current bar One of three problems might exist 1 1The item...

Page 171: ...ound warning prevents testing Answer these questions Has the unit recently been moved to a new location where the outlet might not be grounded Is the unit being operated in a field where the AC power...

Page 172: ...e lead wire for any cuts or nicks in the wire sheath 2 Take the clip in one hand and grip the lead wire in the other had approximately 12 18 inches from the clip 3 Grip the lead wire approximately six...

Page 173: ...ntact the SKF service department for assistance Third party software warning NOTICE Even though Windows XP Embedded does not allow the installation of general software packages do not install spyware...

Page 174: ...ess _______________________ Shipping Address ____________________ Phone Number _____________________ Fax ______________________________ From the name plate on the back of the analyzer SKF Product Numb...

Page 175: ...kV Baker AWA IV 4 kV Output voltage 0 2160 volts 0 4250 volts Max output current 200 amps 400 amps Pulse energy 2 joules 9 joules Storage capacitance 1F 1 F Sweep range 2 5 200 S Div 2 5 200 S Div Vol...

Page 176: ...curacy 10 100 1 5 2 20 1 5 2 2 05 5 05 6 005 5 005 07 0002 5 001 01 0001 5 Above 100 is reported as a potentially open circuit Table 12 Testing accuracy for HiPot measurements Range Approximate maximu...

Page 177: ...00 volts 0 12000 volts 0 12000 volts Max output current 800 amps 800 amps 800 amps Current resolution 1 1 10 100 amps division 1 1 10 100 amps division 1 1 10 100 amps division Overcurrent trip settin...

Page 178: ...eparate test leads Range Full scale accuracy 10 50 5 2 20 5 2 2 5 05 6 5 005 07 5 001 01 5 Above 50 is reported as a potentially open circuit Table 19 Testing accuracy for HiPot Measurements Range App...

Page 179: ...2 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 Voltage Machines...

Page 180: ...onal Electrical Manufacturers Association NEMA Global Engineering Documents Phone 1 800 854 7179 International 303 379 2740 160 PUB CM I4 71 015 EN V13 2 Static Motor Analyzer Baker AWA IV User Manual...

Page 181: ...ly generated when a new motor is added The Motor ID field is a unique identifier that the user gives each motor Table 21 Field name descriptions Field name Type Description motor_key Long integer Auto...

Page 182: ...mbient temperature at which the motor can operate and still be within the tolerance of the insulation class at the max temperature rise in C duty_cycle Text 16 Defines the length of time during which...

Page 183: ...if any use Text 25 Enter how the motor is being used verthoriz Text 16 Enter vertical or horizontal mounting starter Text 16 Motor starter type start24h Text 16 Number of starts per 24 hours percentld...

Page 184: ...for lead 1 resist_balance2 Double Balance resistance for lead 2 resist_balance3 Double Balance resistance for lead 3 resist_12 Double Lead 1 to lead 2 resistance resist_23 Double Lead 2 to lead 3 resi...

Page 185: ...s been conducted DA Only DPASS DFAIL pi_whyFailed Text 25 Reason why motor failed if it failed pi_voltage Short integer Test voltage for PI test pi_da_ratio Double 3 minute resistance value divided by...

Page 186: ...reached for lead 3 surge_ear1_2 Short integer Error Area Ratio lead 1 to lead 2 surge_ear1_3 Short integer Error Area Ratio lead 1 to lead 3 surge_ear_2_3 Short integer Error Area Ratio lead 2 to lea...

Page 187: ...n micro amps 120 seconds piamps150 Double Current in micro amps 150 seconds piamps180 Double Current in micro amps 180 seconds piamps240 Double Current in micro amps 240 seconds piamps300 Double Curre...

Page 188: ...es420 Double Resistance in Meg Ohms 420 seconds pires480 Double Resistance in Meg Ohms 480 seconds pires540 Double Resistance in Meg Ohms 540 seconds pires600 Double Resistance in Meg Ohms 600 seconds...

Page 189: ...step_time Short integer Length of step in seconds step_ramp_rate Short integer Not used at this time step_min_Meg Ohm Long integer Minimum Meg Ohms aloud for the step Meg Ohm_at_endstep Long integer M...

Page 190: ...xis volts per div microSecPerPnt Double Micro seconds per point Not used voltsPerPnt Double Volts per point Not used at this time wave1Full Full waveform for lead 1 wave1Mid Middle waveform for lead 1...

Page 191: ...MATIC MANUAL or UNKNOWN temp_enabled Yes No Temperature test 1 on 0 off resist_enabled Yes No Resistance test 1 on 0 off Meg Ohm_enabled Yes No Meg Ohm test 1 on 0 off pi_enabled Yes No PI test 1 on 0...

Page 192: ...esist_temp_correct_factor Double Default 234 5 for copper resist_target_coilRes_enabled Yes No 1 Coil resistance checking enabled 0 not enabled resist_target_coilRes Double Coil resistance to compare...

Page 193: ...s to discharge pi_PowerPack_enabled Yes No 1 PP enabled 0 No PP Table 38 Test results parameters table HiPot test parameters field descriptions Field name Type Description HiPot_test_voltage Short int...

Page 194: ...power pack 8000 4 Auto scale surge_PauseBetweenLeads Yes No 1 Yes pause 0 No do not pause surge_zero_enabled Yes No Zero tolerance error checking on off surge_zero_percent Short integer Zero tolerance...

Page 195: ...identifier that the user gives each set of test criteria to identify what motor s is meant to be tested For example 480 V w o PI Table 41 Test ID table field descriptions Field name Type Description...

Page 196: ...testing resist_isAuto Yes No 1 Automatic 0 Manual resist_4lead_test_enabled Yes No 1 4 lead test enabled 0 4 lead test disabled Only disabled at this time resist_correct_to_temp_enabled Yes No Correc...

Page 197: ...voltage of test pi_min_Meg Ohm Short integer Minimum Meg Ohm value pi_min_ratio Double Length of test pi_ramp_rate Short integer Ramp rate pi_trip_level Short integer HiPot trip value pi_da_only_enabl...

Page 198: ...pack 1000 1 500 w power pack 2000 2 1000 w power pack 4000 3 2000 w power pack 8000 4 Auto scale surge_PauseBetweenLeads Yes No 1 Yes pause 0 No do not pause surge_zero_enabled Yes No Zero tolerance e...

Page 199: ...ltage test ID table TestIdPrgHiPot Table 49 Step Voltage Test ID table fields descriptions Field name Type Description test_key Long integer Test identification key test_voltage Long integer Voltage f...

Page 200: ...eger Scale index for the x axis micro seconds per division Yscale Integer Scale index for the y axis volts per division MicroSecPerPnt Double Microseconds per point Not used at this time VoltsPerPnt D...

Page 201: ...ntains the field description used tree_level_2_field_name Text 10 Motor Location field used for this database default is Building The record with the most recent date contains the field description us...

Page 202: ...182 PUB CM I4 71 015 EN V13 2 Static Motor Analyzer Baker AWA IV User Manual Database definition...

Page 203: ...st results Fail OPEN LEADS Open Leads Detected FAIL TOLERANCE Test Results Fail TOLERANCE Resistance s outside of user defined targeted range CAUTION Reistance out of range Resistance values must be g...

Page 204: ...D FAIL Low PRG HPT voltage The last step voltage is below the previous Meg Ohm PI test voltage Surge test failure types Status Failure type Failure message FAIL Open leads Test Results Fail OPEN LEADS...

Page 205: ...roper winding connection or circuit shorting Insulation resistance Low MegOhms Indication of significant thermal degradation contamination of moisture influences Insulation resistance Overcurrent trip...

Page 206: ...186 PUB CM I4 71 015 EN V13 2 Static Motor Analyzer Baker AWA IV User Manual...

Page 207: ...ers indicators and common causes 185 AWA IV troubleshooting 147 B Baker AWA IV 2 kV 4 kV model front panel 23 Baker AWA IV 2 kV and 4 kV tester specifications 155 Baker AWA IV 6 kV 12 kV and 12 kVHO t...

Page 208: ...g DA PI tests 87 Configuring DC tests 87 Configuring HiPot test 87 Configuring MegOhm test 87 Configuring Ramp Voltage test 87 Configuring Step Voltage test 87 Configuring Temperature Resistance test...

Page 209: ...ltage test leads 24 Hi L in Baker AWA IV 2 kV and Baker AWA IV 4 kV 109 HiPot 74 HiPot display checks 150 HiPot overcurrent trip check 151 HiPot test 79 I information devices 1 Insulation Resistance M...

Page 210: ...0 Recommended test voltages for insulation resistance testing 80 Reference Surge waveform table RefSrgWaveForm 180 Relative humidity 75 Renaming a route 39 Repair parts 147 Resistance failure types 18...

Page 211: ...e phase test lead power pack 130 Testing with the Baker PP30 three phase test lead power pack 124 Test lead connection 26 Test Params feature 48 Test results parameters table TestResultsParameters 171...

Page 212: ...PUB CM I4 71 015 EN V13 2 Static Motor Analyzer Baker AWA IV User Manual Index W Warranty return 154 Warranty return form 154 Window menu 34 Work list table Route 181 Wye wound resistance measurement...

Page 213: ......

Page 214: ...rings and units Seals Lubrication systems Mechatronics Services The Power of Knowledge Engineering Drawing on five areas of competence and application specific expertise amassed over more than 100 yea...

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