SKF Baker AWA-IV 2 kV, Baker AWA-IV 4 kV User Manual

SKF Static Motor Analyzer

Baker AWA-IV

User manual

SKF Static Motor Analyzer

Baker AWA-IV

User manual

Part number: 71-015 EN

Revision: V13.2

March, 2018

Copyright © 2018 by SKF USA, Inc.

All rights reserved.

SKF USA, Inc.

4812 McMurry Ave. Suite 100

Fort Collins, CO 80525

(970) 282-1200

(970) 282-1010 (FAX)

800-752-8272 (USA Only) http://www.skf.com/group/products/condition-monitoring/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) 496-3627.

NOTICE

SKF USA, Inc. assumes no liability for damages consequent to the use of this product.

SKF Patents

#US04768380 • #US05679900 • #US05845230 • #US05854553 • #US05992237 •

#US06006164 • #US06199422 • #US06202491 • #US06275781 • #US06489884 •

#US06513386 • #US06633822 • #US6,789,025 • #US6,792,360 • US 5,633,811 • US

5,870,699 • #WO_03_048714A1

Notices

CAUTION

This equipment has been tested and found to comply with the limits for a

Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference with the equipment is operated in its installation.

This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the product manual, could cause harmful interference to radio communications. If this equipment does cause harmful interference, the user will be required to correct the interference. Due to the phenomena being observed and the material properties being measured, this equipment radiates radio frequency energy while in the active test mode. Care should be taken to ensure this radio frequency energy causes no harm to individuals or other nearby equipment.

Information 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 other rights of third parties that may result from its use. No license is granted by implication or otherwise under any patent rights of SKF USA, Inc.

SKF USA, Inc. assumes no liability for damages consequent to the use of this product. No part of this document may be reproduced in part or in full by any means such as photocopying, photographs, electronic recording, videotaping, facsimile, etc. without written permission from SKF USA, Inc. Fort Collins, Colorado.

Note on software

While the Baker AWA-IV is a Microsoft Windows® based instrument, it is not a computer, which any software available in the market should be installed. The installed applications and

Windows® configuration are set up to operate the Baker AWA-IV hardware. Modifications to this setup may cause unit malfunction.

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Declaration of Conformity

Manufacturer’s Name and Address:

SKF USA, Inc.

4812 McMurry Ave


USA

Equipment Description: Testers for Surge, DC Hi-Pot, and Winding Resistance of motors.

Equipment Model Designations: Baker AWA-IV-2, Baker AWA-IV-4, Baker AWA-IV-6, and

Baker AWA-IV-12.

Application of Council Directive 72/23/EEC on the harmonization of the laws related to

Member States relating to electrical equipment designed for use within certain voltage limits, as amended by: Council Directive 93/68/EEC and Council Directive 89/336/EEC on the approximation 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 properties being measured, this equipment does radiate radio frequency energy while in the active test mode.

Referenced Safety Standards:

EN 61010-1

Referenced EMC Standards:

EN 61326:2001

EN 55011 Class A

EN 61000-3-2

EN 61000-3-3

EN 61000-4-2

EN 61000-4-3

EN 61000-4-5

EN 61000-4-5

EN 61000-4-6

EN 61000-4-11

I, the undersigned, hereby declare that the equipment specified above conforms to the above

Directives and Standards.

Signature:

Printed Name: Mike Teska

Title: Engineering Manager

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Notices

End-User License Agreement – EMCM Software

THIS END-USER LICENSE AGREEMENT (this “Agreement”) is entered into by and between

SKF USA Inc. and/or SKF Condition Monitoring - Fort Collins (hereinafter referred to collectively as the “Licensor”) and any person or business that executes this Agreement by clicking the “I agree” icon at the end of this Agreement or by accessing, using, or installing the

Software (“Licensee” or “You”). Licensor and Licensee shall be referred to collectively in this

Agreement as the Parties.

BY CLICKING THE ACCEPTANCE BUTTON OR ACCESSING, USING, OR INSTALLING THE

SOFTWARE, OR ANY PART THEREOF, YOU EXPRESSLY AGREE TO BE BOUND BY ALL OF

THE TERMS OF THIS AGREEMENT. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF

THIS AGREEMENT, THE BUTTON INDICATING NON-ACCEPTANCE MUST BE SELECTED,

AND YOU MAY NOT ACCESS, USE, OR INSTALL ANY PART OF THE SOFTWARE.

1. DEFINITIONS

(1a) Derivative Works.

The Term “Derivative Works” shall have the same meaning as set forth in the U.S. Copyright

Act, as amended from time to time, in title 17 of the United States Code.

(1b) Effective Date.

The term “Effective Date” shall mean the date on which Licensee assents to the terms of this

Agreement by clicking the “I agree” button at the bottom of this Agreement.

(1c) Intellectual Property Rights.

The term Intellectual Property Rights shall mean all rights arising or protectable under the copyright, 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 “Person” shall mean an individual, a partnership, a company, a corporation, an association, a joint stock company, a trust, a joint venture, an unincorporated organization, or a governmental entity (or any department, agency, or political subdivision thereof).

(1e) Software.

The term “Software” shall mean the software application entitled Surveyor, Surveyor DX,

Surveyor EXP, Surveyor NetEP, Baker AWA-IV, Baker DX, EXP4000, NetEP, MTA, which is an application developed, owned, marketed, and licensed by Licensor.

The term “Software” shall include the object code of software for Surveyor, Surveyor DX,

Surveyor EXP, Surveyor NetEP, Baker AWA-IV, Baker DX, EXP4000, NetEP, MTA or any other object code within the SKF condition monitoring family suite and any and all user manuals, or other technical documentation, authored by Licensor in connection with Software any other software within SKF condition monitoring products.

The term “Software” includes any corrections, bug fixes, enhancements, releases, updates, upgrades, or other modifications, including custom modifications, to Surveyor, Surveyor DX,

Surveyor EXP, Surveyor NetEP, Baker AWA-IV, Baker DX, EXP4000, NetEP, MTA and any and all associated user manuals. The term Software also includes any supplemental, add-on, or plug-in software code provided to Licensee.

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The term “Software” shall not be construed to include the source code for Surveyor, Surveyor

DX, Surveyor EXP, Surveyor NetEP, Baker AWA-IV, Baker DX, EXP4000, NetEP, MTA or any other source code from SKF condition monitoring products.

2. LICENSE

(2a) Grant of License.

Licensor grants Licensee, pursuant to the terms and conditions of this Agreement, a nonexclusive, non-transferable, and revocable license to use the Software in strict accordance with the terms and conditions of this Agreement, including any concurrent use, network or other limitations set forth in subsection (b) below.

All rights not specifically granted by Licensor under this Agreement are retained by Licensor and withheld from Licensee.

(2b) Installation and Use Rights.

Licensee shall use the Software only on its internal computer equipment, whether such equipment is owned, leased, or rented, at the Licensee’s principal business office.

The following paragraphs govern your installation and use rights with regard to the Software, depending on the type of license you have obtained from Licensor.

(i) If you obtained a stand-alone license of the Software, you may install one (1) copy of the

Software on one (1) computer residing in your principal business office.

(ii) If you obtained a network license of the Software, you may install one (1) copy of the

Software on as many networked clients (workstations) as authorized by your network license, as set forth more particularly 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 database residing in your principal business office.

(iii) If you obtained a network license of the Software, you may connect to multiple licensed databases, you may install the database-dedicated clients up to the total number of networked clients acquired by you under the applicable purchase order or other ordering documents memorializing your license acquisition.

(2c) Other Conditions of Use.

None.

(2d) Restrictions on Use.

Licensee may use the Software only for its internal business purposes and on the identified equipment on which the Software was first installed or for which it is otherwise licensed; provided, however, that Licensee may temporarily use the Software on a back-up system in the event that the primary licensed system is inoperative, or test system not used for production but solely for the purposes of testing the Software. Licensee may not use the

Software for any other purpose. Licensee shall not:

(i) permit any parent, subsidiaries, affiliated entities or third parties to use the Software;

(ii) use the Software in the operation of a service bureau;

(iii) allow access to the Software through any workstations located outside of Licensee’s principal business offices;

(iv) rent, resell, lease, timeshare or lend the Software to any Person;

(v) sublicense, assign, or transfer the Software or this license for the Software to any Person;

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(vi) reproduce, distribute, or publicly display the Software;

(vii) make the Software accessible to any Person by any means, including posting on a web site or through other distribution mechanisms over the Internet;

(viii) reverse assemble, disassemble, reverse engineer, reverse compile, decompile, or otherwise translate the Software or prepare Derivative Works based on the Software;

(ix) place, reproduce, or make available the Software on Licensee’s computer network if

Licensee is only authorized by this Agreement to operate the Software on a single workstation;

(x) exceed at any given point in time the total number of network clients authorized by the applicable purchase order or ordering document to use or access the Software;

(xi) edit or modify the Software except as expressly authorized by Licensor, including altering, deleting, or obscuring any proprietary rights notices embedded in or affixed to the Software;

(xii) use the Software in any manner that disparages Licensor, Microsoft, or Oracle, or use the

Software in a way that infringes the Intellectual Property Rights of the foregoing parties; or

(xiii) use the Software in a manner that violates any federal, state, or local law, rule or regulation, or use the Software to violate the rights of any third party, or use the Software to promote pornography, hatred, or racism.

(2e) Copies.

Licensee, solely to enable it to use the Software, may make one archival copy of the

Software’s computer program, provided that the copy shall include Licensor’s copyright and any other proprietary notices. The Software delivered by Licensor to Licensee and the archival copy shall be stored at Licensee’s principal business office. If you purchased a site license of the Software, licensee 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 paragraph, Licensee shall have no other right to copy, in whole or in part, the Software. Any copy of the Software made by Licensee is the exclusive property of Licensor.

(2f) Modifications.

Licensee agrees that only Licensor shall have the right to alter, maintain, enhance or otherwise modify the Software.

(2g) Protection of Software.

Licensee agrees that it will take action by instruction, written agreement, or otherwise as appropriate with any person permitted access to the Software to enable Licensee to comply with its obligations hereunder. Licensee shall maintain records of the number and location of all copies of Software. Licensee shall not provide, permit access to or use of, or otherwise make available any Software in any form without Licensor’s prior written agreement, except to Licensee’s employees for purposes specifically authorized by this Agreement. Licensee understands and agrees that the source code for the Software is a valuable copyright and contains valuable trade secrets of Licensor. Licensee agrees not to discover or attempt to discover, or assist or permit any Person to discover or attempt to discover, by any means whatsoever the source code of the Software.

(2h) Licensor’s Audit Rights.

Licensor shall possess the right to audit Licensee’s use of the Software to determine compliance with this Agreement (hereinafter referred to as “Licensor’s Audit Rights”).

Licensor’s Audit Rights shall be exercised in accordance with the following paragraphs:

(i) Notice of Audit. Licensor shall provide Licensee with at least five (5) calendar days advance written notice of its intent to exercise the Licensor’s Audit Rights.

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(ii) Conduct of Audit. The audit conducted by Licensor shall consist of a physical review of the computer hardware, software, and middleware operated by Licensee at its principal business office and any other office for which Licensor, in its sole and arbitrary discretion, deems an audit appropriate. Licensee shall provide Licensor with unrestricted access to its computer hardware, software, and middleware in connection with any audit conducted by Licensor.

(iii) Costs of Audit. If Licensor’s audit uncovers a violation of this Agreement by Licensee,

Licensee shall pay all costs and expenses incurred by Licensor in exercising the Licensor

Audit Rights, including, without limitation, all attorneys’ fees and agent fees incurred by

Licensor. If Licensor concludes that no violation of this License Agreement has occurred,

Licensor shall bear all costs and expenses incurred in exercising the Licensor Audit Rights. If

Licensee obstructs, restricts, or otherwise prevents Licensor from conducting a full and unrestricted audit, Licensee shall bear all costs and expenses, including attorneys’ fees, incurred by Licensor in enforcing this Section 2h before any court or judicial tribunal.

(iv) Frequency of Audits. Licensor’s Audit Rights shall be exercised no more than two (2) times in any one calendar year.

(2i) Validity of Intellectual Property Rights.

In any action, dispute, controversy, or lawsuit arising out of or related to this Agreement,

Licensee shall not contest the validity of Licensor’s Intellectual Property Rights related to the

Software. Licensee hereby agrees that it has had an opportunity to investigate the validity 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 specifically agrees that each of the terms and conditions of this Section 2 are material and that failure of Licensee to comply with these terms and conditions shall constitute sufficient cause for Licensor to terminate this Agreement and the license granted hereunder immediately and without an opportunity to cure. This subsection 2(j) shall not be construed to preclude, or in any way effect, a finding of materiality with respect to any other provision of this Agreement.

3. LICENSE FEE

The applicable licensee fees will be set forth in the quote issued to Licensee by Licensor or otherwise established in the applicable purchase order or other ordering documents memorializing your license acquisition.

4. OWNERSHIP

(4a) Title.

Licensee understands and agrees that Licensor owns all Intellectual Property Rights related to the Software, including custom modifications to the Software, whether made by Licensor or any third party. Licensee agrees that this Agreement effects a license, not a sale, of the

Software and that the first sale doctrine, as codified in 17 U.S.C. § 109, does not apply to the transaction effected by this Agreement.

(4b) Transfers.

Under no circumstances shall Licensee sell, license, sublicense, publish, display, distribute, assign, or otherwise transfer (hereinafter referred to collectively as a “Transfer”) to a third party the Software or any copy thereof, in whole or in part, without Licensor’s prior written consent. Any Transfer effected in violation of this Section 4b shall be void ab initio and of no force or effect.

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5. MAINTENANCE AND SUPPORT

Licensor may provide you with support services related to the Software called Product

Support Plan (“PSP”) services. Use of PSP is governed by the policies and programs described in the PSP literature or other material from Licensor’s Product Support

Department (hereinafter referred to as the “PSP Policies”) that may be updated by Licensor from time to time. If you select and pay for PSP, the PSP Policies shall be specifically incorporated into this Agreement by this reference. Licensee acknowledges that Licensor may use any technical information provided by Licensee in the course of receiving PSP services for Licensor’s business purposes, including for product support and development. Licensor will not utilize such technical information in a manner that identifies Licensee.

6. CONFIDENTIAL INFORMATION

Licensee agrees that the Software contains proprietary information, including trade secrets, know-how and confidential information (hereinafter referred to collectively as the

“Confidential Information”), that is the exclusive property of Licensor. During the period this

Agreement is in effect and at all times after its termination, Licensee and its employees and agents shall maintain the confidentiality of the Confidential Information and shall not sell, license, publish, display, distribute, disclose or otherwise make available the Confidential

Information to any Person nor use the Confidential Information except as authorized by this

Agreement. Licensee shall not disclose the Confidential Information concerning the Software, including any flow charts, logic diagrams, user manuals and screens, to persons not an 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 period of 365 days from the date of shipment of the Software; provided, however, that the foregoing warranty only applies if:

(i) Licensee makes Licensor aware of any defect with the Software within seven (7) days after the occurrence of the defect;

(ii) Licensee has paid all amounts due under this Agreement; and

(iii) Licensee has not breached any provision of this Agreement.

The foregoing warranty does not apply in the event that:

(i) the Software and documentation have been subject to misuse, neglect, alteration, modification, customization, improper installation, and/or unauthorized repair;

(ii) the Software or any associated software or equipment have not been properly maintained in accordance with applicable specifications and industry standards or have been maintained in unsuitable environmental conditions; or

(iii) Licensee has used the Software in conjunction with other equipment, hardware, software, or other technology that created an adverse impact on the operation, functioning, or performance of the Software.

(7b) EXCEPT AS SET FORTH IN THIS SECTION 7 AND TO THE EXTENT PERMITTED BY

APPLICABLE LAW, ALL EXPRESS AND/OR IMPLIED WARRANTIES OR CONDITIONS,

INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OR CONDITIONS OF

MERCHANTABILITY, MERCHANTABILITY OF A COMPUTER PROGRAM, INFORMATIONAL

CONTENT, SYSTEM INTEGRATION, FITNESS FOR A PARTICULAR PURPOSE, AND NON-

INFRINGEMENT, ARE HEREBY DISCLAIMED AND EXCLUDED BY LICENSOR.

(7c) The remedies set forth in this Section 7 are the exclusive remedies available to

Licensee for any problem in the performance of the Software.

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8. LIMITATIONS ON LIABILITY

(8a) Limitations and Exclusions.

IN NO EVENT WILL LICENSOR BE LIABLE TO LICENSEE FOR ANY DIRECT, INDIRECT,

INCIDENTAL, CONSEQUENTIAL, PUNITIVE OR OTHER SPECIAL DAMAGES, LOST PROFITS,

OR LOSS OF INFORMATION SUFFERED BY LICENSEE ARISING OUT OF OR RELATED TO

THIS AGREEMENT OR THE USE OF THE SOFTWARE, FOR ALL CAUSES OF ACTION OF ANY

KIND (INCLUDING TORT, CONTRACT, NEGLIGENCE, STRICT LIABILITY, BREACH OF

WARRANTY OR CONDITION, AND STATUTORY) EVEN IF LICENSOR HAS BEEN ADVISED OF

THE POSSIBILITY OF SUCH DAMAGES. THE PRECEDING EXCLUSION AND DISCLAIMER OF

DAMAGES SHALL APPLY TO ALL CLAIMS MADE BY LICENSEE RELATED TO OR ARISING

OUT OF LICENSEE’s USE OF THE SOFTWARE, INCLUDING, BUT NOT LIMITED TO, CLAIMS

ALLEGING THAT THE SOFTWARE, OR ANY COMPONENT THEREOF, FAILED OF ITS

ESSENTIAL PURPOSE OR FAILED IN SOME OTHER RESPECT.

(8b) Acknowledgment.

Licensee agrees that the limitations of liability and disclaimers of warranty set forth in this

Agreement will apply regardless of whether Licensor has tendered delivery of the Software or Licensee has accepted the Software. Licensee acknowledges that Licensor has set its prices and entered into this Agreement in reliance on the disclaimers of warranty and the limitations and exclusions of liability set forth in this Agreement and that 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 terminated in accordance with Section 9b below.

(9b) Termination.

Licensor may terminate this Agreement and the license conveyed hereunder in the event that

Licensee breaches any provision, term, condition, or limitation set forth in this Agreement, including but not limited to the license restrictions set forth in Section 2d of this Agreement.

(9c) Effect of Termination.

Within ten (10) days after termination of this Agreement and the license granted hereunder,

Licensee shall return to Licensor, at Licensee’s expense, the Software and all copies thereof, and deliver to Licensor a certification, in writing signed by an officer of Licensee, that all copies of the Software have been returned to Licensor and that Licensee has discontinued its use of the Software.

10. ASSIGNMENT

Licensee shall not assign or otherwise transfer the Software or this Agreement to anyone, including any parent, subsidiaries, affiliated entities or third Parties, or as part of the sale of any portion of its business, or pursuant to any merger, consolidation or reorganization, without Licensor’s prior written consent. Any assignment or transfer effected in violation of this Section 10 shall be void ab initio and of no force or effect.

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11. FORCE MAJEURE

Neither party shall be in default or otherwise liable for any delay in or failure of its performance under this Agreement if such delay or failure arises by any reason beyond its reasonable control, including any act of God, any acts of the common enemy, the elements, earthquakes, floods, fires, epidemics, riots, failures or delay in transportation or communications; provided, however, that lack of funds shall not be deemed to be a reason beyond a party’s reasonable control. The Parties will promptly inform and consult with each other as to any of the above causes that in their judgment may or could be the cause of a delay in the performance of this Agreement.

12. NOTICES

All notices under this Agreement are to be delivered by depositing the notice in the mail, using registered mail, return receipt requested, to the party’s last known principal business address or to any other address as the party may designate by providing notice. The notice shall be deemed delivered four (4) days after the notice’s deposit in the mail, if such notice has been sent by registered mail.

13. CHOICE OF LAW

This Agreement (including all Exhibits), including its formation, execution, interpretation, and performance, and the rights and obligations of the Parties hereunder, shall be governed by and construed in accordance with the laws of the Commonwealth of Pennsylvania, without regard to any conflicts of law (or choice of law) principles thereof.

14. CONSENT TO JURISDICTION

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 in or for Philadelphia, Pennsylvania for the purposes of any suit, action or other proceeding relating to arising out of this Agreement or any transaction contemplated hereby or thereby (“Legal Proceedings”). Licensee further agree that service of any process, summons, notice, or document by U.S. registered mail to such Party’s respective address shall be effective service of process for any Legal Proceeding. Licensor and Licensee irrevocably and unconditionally waive any objection to personal jurisdiction and/or the laying of venue of any Legal Proceeding in the state or federal court in or for Philadelphia,

Pennsylvania, and hereby further irrevocably and unconditionally agree not to plead, argue, or claim in any such court that any Legal Proceeding brought in any such court has been brought in an inconvenient forum and otherwise waive any and all objections to the forum.

15. EXPORT CONTROLS

Licensee shall not export or reexport, directly or indirectly, the Software without complying with the export controls imposed by the United States Export Administration Act of 1979, as amended (or any future U.S. export control legislation) and the regulations promulgated thereunder.

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16. GOVERNMENT END USERS

If Licensee is acquiring the Software for or on behalf of a subdivision of the U.S. federal government, this Section 16 shall apply. The Software was developed completely at private

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Information Act, is “restricted computer software” and in all respects proprietary data belonging solely to Licensor, and all rights are reserved under the copyright laws of the

United States. Use, duplication, or disclosure by the Government is subject to restricted rights as set forth in subparagraphs (a) through (d) of the Commercial Computer Software

Restricted Rights clause at FAR 52.227-19, or for DoD units, the restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at

DFARS 252.227-7013.

17. TRADEMARKS

Licensee agrees that SKF Surveyor, Surveyor DX, Surveyor EXP, Surveyor NetEP, Baker

AWA-IV, Baker DX, EXP4000, NetEP, MTA or any other software within SKF’s condition monitoring product line and the trade dress, logos and other designations of source used by

Licensor to identify the Software are trademarks or registered trademarks of Licensor.

Licensee shall not use Licensor’s trademarks or service marks without the prior written consent of Licensor. If the Software contains any active links to web sites, you agree to maintain such active links and not redirect or modify them.

18. GENERAL PROVISIONS

(18a) Complete Agreement.

The Parties agree that this Agreement is the complete and exclusive statement of the agreement between 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 Agreement may not be modified, altered or amended except by written instrument duly executed by both Parties. Any purchase orders or other ordering documents issued to

Licensee by Licensor shall not have the effect of amending or modifying this Agreement, and shall only serve to memorialize the number of licenses or products ordered by Licensee. In the event of a conflict between the PSP Policies and this Agreement, the terms of this

Agreement shall control.

(18c) Waiver.

The waiver or failure of either party to exercise in any respect any right provided for in this

Agreement shall not be deemed a waiver of any further right under this Agreement.

(18d) Severability.

If any provision of this Agreement is invalid, illegal or unenforceable under any applicable statute or rule of law, it is to that extent to be deemed omitted. The remainder of the

Agreement shall be valid and enforceable to the maximum extent possible.

(18e) Read and Understood.

Each party acknowledges that it has read and understands this Agreement and agrees to be bound by its terms.

(18f) Limitations Period.

No action arising under, or related to, this Agreement, may be brought by either party against the other more than two (2) years after the cause of action accrues, unless the cause of action involves death or personal injury.

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(18g) Attorneys’ Fees.

In the event any litigation is brought by either party in connection with this Agreement, the prevailing party in such litigation will be entitled to recover from the other party all the costs, reasonable attorneys’ fees, and other expenses incurred by such prevailing party in the litigation.

(18h) Authorized Representative.

The person installing or using the Software on behalf of Licensee represents and warrants that he or she is legally authorized to bind Licensee and commit Licensee to the terms of this

Agreement.

(18i) Injunctive Relief.

Licensee agrees that Licensor may suffer irreparable harm as a result of a violation 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 seek and obtain, in addition to such other monetary relief as may be recoverable at law or in equity, such injunctive other equitable relief as may be necessary to restrain any threatened, continuing, or further breach by Licensee without showing or proving actual damages sustained by Licensor and without posting a bond.

® SKF and @ptitude are registered trademarks of the SKF Group.

Microsoft®, Microsoft Windows®, Micorsoft Windows 7 Extended® are registered trademarks of Microsoft Corporation.

All other trademarks are the property of their respective owners.

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Table of contents

1 About this manual 1

Formatting ............................................................................................................................ 1

Information devices .............................................................................................................. 1

2 Safety and general operating information 3

Symbols on equipment ........................................................................................................ 3

Labels on equipment ............................................................................................................ 3

Safety precautions ................................................................................................................ 4

Test related................................................................................................................................ 4

General ..5

Emergency stop button ........................................................................................................ 6

Baker ZTX E-stop and remote E-stop ................................................................................ 7

General operation, maintenance, and service information ............................................. 8

Cleaning and decontamination ................................................................................................ 8

Technical assistance / 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 shipping positions .....................................................................................10

3 Database management and maintenance 11

Database management ......................................................................................................11

Consequences of not organizing data ....................................................................................11

Starting the software ........................................................................................................12

Creating a new database ...................................................................................................12

Opening an existing database ...........................................................................................13

Using multiple databases ...................................................................................................14

Data Transfer feature ..........................................................................................................15

Transferring motor and test results data ...............................................................................15

Transferring Test IDs ...............................................................................................................18

Archiving a database .........................................................................................................19

Restoring a database ..........................................................................................................20

Table of Contents

4 Baker AWA-IV instrument overview 23

Baker AWA-IV 2 kV/4 kV model front panel ....................................................................23

VGA port 23

USB ports ...............................................................................................................................23

Ethernet connector .................................................................................................................23

Emergency power shut-off ....................................................................................................24

Resistance leads .....................................................................................................................24

High-voltage test leads ..........................................................................................................24

Voltage output control knob (6 kV and 12 kV models only) .................................................24

Baker AWA-IV 6 kV/12 kV model front panel .................................................................24

Baker AWA-IV 6 kV model distinctions .................................................................................25

Setting up the Baker AWA-IV tester .................................................................................25

Selecting an optimal environment .........................................................................................25

Making basic connections and starting 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

Opening an existing database ...........................................................................................29

Using version 4 software for the first time ......................................................................30

Main window ......................................................................................................................31

Main menu ...........................................................................................................................32

File menu ................................................................................................................................32

View menu ..............................................................................................................................33

Database menu ......................................................................................................................34

Window menu.........................................................................................................................34

Tools menu ..............................................................................................................................35

Help menu ..............................................................................................................................35

Toolbar ..................................................................................................................................36

Tabs .......................................................................................................................................37

Explore tab ..............................................................................................................................37

Motor ID tab ............................................................................................................................38

Route tab.................................................................................................................................39

Modifying the display of lists in the Motor ID and Route tabs ...............................................41

Viewing test data .................................................................................................................42

Using the Data tab ..............................................................................................................43

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

Table of Contents

Motor location fields ...............................................................................................................44

Motor ID field ..........................................................................................................................44

Data tab—Nameplate view ....................................................................................................45

Data tab—Application view ....................................................................................................47

Data tab—Results Summary view ........................................................................................49

Data tab—Surge view ............................................................................................................50

Data tab—PI view ..................................................................................................................52

Data tab—Step/Ramp-Voltage view .....................................................................................53

Using the Tests tab ..............................................................................................................55

Test configuration ..............................................................................................................56

Temperature/Resistance test setup window ..........................................................................56

Manually entering resistance measurements .......................................................................59

DC Tests setup window ...........................................................................................................60

Surge test setup window ........................................................................................................63

E bar graph .............................................................................................................................65

Creating a Surge test reference .............................................................................................66

Viewing Surge test 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 procedures 77

Before testing begins ..........................................................................................................77

Recommended testing sequence ......................................................................................77

Balance resistance test or line-to-line resistance .................................................................78

MegOhm test .........................................................................................................................78

DA/PI test ................................................................................................................................78

HiPot test ................................................................................................................................79

Step Voltage test .....................................................................................................................79

Surge test ................................................................................................................................79

Recommended test voltages for insulation resistance testing ......................................80

Recommended test voltages for HiPot and Surge tests ................................................80

Performing an example test ..............................................................................................81

Creating a Motor ID ................................................................................................................81

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

Table of Contents

Creating a Test ID ....................................................................................................................83

Configuring Temperature/ Resistance test .............................................................................85

Configuring DC tests ...............................................................................................................87

Configure Surge test ...............................................................................................................89

Running an automatic test .....................................................................................................91

Reviewing test results/data ................................................................................................95

Printing reports ...................................................................................................................98

Creating a new motor voltage class ............................................................................... 103

Surge testing notes and recommendations ................................................................. 104

Surge testing with rotor removed (typically motor shop testing)........................................104

Surge testing with rotor installed (typically field testing) ....................................................104

Surge testing DC motors ......................................................................................................104

False P-P EAR failures .........................................................................................................104

Surge test underpowered .....................................................................................................104

Surge testing through capacitors .........................................................................................105

7 Special features of the Baker AWA-IV 107

Predictive maintenance ................................................................................................... 107

Quality control .................................................................................................................. 108

Motor troubleshooting .................................................................................................... 108

Field coils ........................................................................................................................... 108

Hi L in Baker AWA-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-IV host and power pack tests ................................................. 119

Creating IDs and setting up the test.....................................................................................119

Running the combined Baker AWA-IV and power pack tests .................................... 122

Testing with the Baker PP30 three-phase test lead power pack ............................... 124

Conducting DC tests with the Baker PP30 three-phase test lead power pack ..................125

Conducting Surge tests with the Baker PP30 three-phase test lead power pack .............127

Testing with the Baker PP24 single-phase test lead power pack .............................. 130

Conducting DC tests with the Baker PP24 single-phase test lead power pack .................130

Conducting Surge tests with the Baker PP24 single-phase test lead power pack ............131

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

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9 Using the Baker ZTX with Baker AWA-IV analyzers 133

Principles of armature insulation testing ..................................................................... 133

Connecting Baker AWA-IV to the Baker ZTX accessory .............................................. 134

Armature preparation ..........................................................................................................135

Configuring a Surge test for armature bar-to-bar testing ......................................... 136

Reviewing test results/data ............................................................................................. 142

Printing reports ................................................................................................................ 144

Generating CSV files .............................................................................................................145

Appendix A — Baker AWA-IV troubleshooting 147

Self-help and diagnostics ............................................................................................... 147

Repair parts ...................................................................................................................... 147

Step #1: Basic information ............................................................................................ 147

Step #2: Applications or service problem? ................................................................... 148

Applications: What to do first .......................................................................................... 148

Common application problems ............................................................................................148

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

Checking test leads for broken sections ........................................................................ 152

Manual break check ......................................................................................................... 152

Overcurrent trip test ........................................................................................................ 152

Open circuit test to verify analyzer operation ............................................................... 152

Third-party software warning ....................................................................................... 153

Warranty return ............................................................................................................... 154

Warranty return form ...........................................................................................................154

Appendix B — Technical specifications and applicable standards 155

Calibration information ................................................................................................... 155

Baker AWA-IV 2 kV and 4 kV tester specifications ...................................................... 155

Baker AWA-IV 6 kV, 12 kV, and 12 kVHO tester specifications .................................. 157

Applicable standards ....................................................................................................... 159

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

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Appendix C — Database definition 161

Version 4.0 database definition ..................................................................................... 161

Nameplate table—(MotorID) .......................................................................................... 161

Test results table—(TestResults).................................................................................... 162

Memo table—(Memo) ..................................................................................................... 166

Polarization Index Test Results table—(TestResultsPI) ............................................... 167

Step Voltage test results table—(TestResultsPrgHiPot) .............................................. 169

Surge test results table—(SurgeWaveform) ............................................................... 170

Test results parameters table—(TestResultsParameters) .......................................... 171

Test ID table—(TestId) ..................................................................................................... 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—(MotorVoltageClasses) ..................................................... 181

Appendix D — Baker AWA-IV specific winding faults 183

Software fault messages................................................................................................ 183

Resistance failure types ................................................................................................... 183

DC test failure types ......................................................................................................... 184

Surge test failure types ................................................................................................... 184

Fault analysis chart .......................................................................................................... 185

AWA-IV static testing parameters, indicators, and common causes ......................... 185

Index 187

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

1 About this manual

This manual uses the following conventions in formatting, and informational devices to help you clearly identify specific elements and information.

Formatting

Interface items are set in Initial Caps and Bold .

Page or window names are set in italics .

File names are set in courier font.

Information devices

Information requiring special attention 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 information about product usage that can result in difficulty using product, a loss of data, or minor equipment damage if not heeded.

CAUTION

Indicates a hazardous situation with potential for minor to moderate injury or property damage, or moderate to severe damage to the product.

WARNING

Indicates a hazardous situation with risk of serious bodily injury or death.

About this manual

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

2 Safety and general operating information

Symbols on equipment

Table 1. Symbols and labels used on equipment.

Symbol/Label Description

Protective conductor terminal. Located beside black ground test lead on front panel of instrument.

Frame or chassis terminal. 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 of instrument and on back of unit.

Labels on equipment

The following Danger notice label appears on all four sides of the power pack units used with the Baker AWA-IV and on the top of the Baker AWA-IV unit itself.

Figure 1. High voltage warning label.

Safety and general operating information

The following safety labels are found on the right side of the power packs:

Figure 2. Power pack lead safety labels.

Safety precautions

Read and follow all safety precautions and safe operating practices in your manual. Do not exceed maximum operating capabilities of the Baker AWA-IV tester, power packs, or the

Baker ZTX accessory.

The general safety information presented here is for both operating and service personnel.

You will find specific warnings and cautions throughout this manual where they apply.

If using the equipment in any manner not specified by SKF USA, Inc. the protection provided by the equipment may be impaired.

WARNING

Failure to heed the following safety precautions can result in injury or death from severe electrical shock.

Test related

• Two-party operation is recommended only when using proper equipment (such as the remote E-Stop) and when taking appropriate precautions so both operators are aware of 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 may result.

• For capacitor-started motors or systems with surge arrestors/power factor capacitors, be sure to disconnect all capacitors from the test circuit before testing.

• Upon completion of any DC-HiPot, megohm, polarization index (PI), step voltage, or dielectric absorption (DA) tests, be sure to short the winding to ground and allow time for discharge before disconnecting the test leads. If you do not do this, voltage may build up on the winding. A common approach is to allow a winding to discharge four times the total amount of time that DC voltage is applied to the winding.

• If the tester is removed from the windings before complete discharge, short winding leads together and ground them using appropriate jumper cables.

• Make sure to disconnect the tester leads before energizing or powering up the motor.



• Never attempt to test a winding with both host and power pack leads attached to the winding at the same time. Damage to the tester will occur.

General

• Do not remove the product covers or panels or operate the tester without the covers and panels properly installed. Components on the inside of the tester carry voltage for operation and can render a shock if touched.

• Use appropriate safety equipment required by your organization, including highvoltage gloves and eye protection.

• The devices covered in this manual are not waterproof or sealed against water entry.

• The devices covered in this manual are intended for indoor use. If using outdoors, you must protect the device(s) from rain, snow, and other contaminants.

• Repair parts warning: 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 manual are grounded through the power cord’s grounding conductor. To avoid electrical shock, plug the power cord into a properly wired/grounded receptacle before connecting the product test leads.

WARNING

DANGER FROM LOSS OF GROUND:

Upon loss of the protective ground connection, all accessible conductive parts, including knobs and controls that may appear to be insulated, can cause an electric shock!

NOTICE

The ground-fault system on the Baker AWA-IV will render it inoperative without a proper ground. When the host Baker AWA-IV tester is connected to a power pack, an inoperable condition will also affect the power pack.

PUB CM/I4 71-015 EN V13.2 Static Motor Analyzer—Baker AWA-IV User Manual 5


Emergency stop button

The Baker AWA-IV tester and the power packs are equipped with a red Emergency Stop

(E-Stop) button on the front panel of the unit. Use it to quickly 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.

Figure 3. Power pack showing Emergency Stop button.



Baker ZTX E-stop and remote E-stop

The Baker ZTX can be used with the Baker AWA-IV 6/12kV models.

The Baker ZTX unit and the remote E-Stop unit are both equipped with a red Emergency

Stop button. The Emergency Stop button is on top of the Baker ZTX unit 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 position until manually retracted by rotating the Emergency Stop button clockwise. A warning message will appear on the Baker

AWA-IV screen.



General operation, maintenance, and service information

Cleaning and decontamination

Keep the unit clean and in a dry environment. To clean the unit, power down and unplug the instrument. Wipe with a clean, water dampened cloth. Do not submerge in water or other cleaners or solvents. To clean the screen, take a soft, water dampened cloth and gently wipe the surface.

Technical assistance / authorized service centers

See our website at www.bakerinst.com for technical assistance / authorized service center information. This information will be marked with an asterisk.

Unpacking the unit

Carefully remove the following items from the shipping box:

• Baker AWA-IV

• Power cord

• Operation manual (soft copy only)

Pollution degree II

(From IEC 61010-1 3.6.6.2) Only non-conductive pollution occurs. However, temporary conductivity caused by condensation is expected.

Power requirements

Using the provided AC power cord, connect the unit to a grounded AC power source. The unit’s power requirements are 100–240 V AC, 50–60 Hz,

2 amps AC maximum current draw. An auto-reset circuit breaker protects the unit.

220/240 VAC units

220/240 VAC input units are indicated by information on the Baker AWA-IV. These units might require you to supply an appropriate AC connector for mating to the power source.

These units are designed for use on a single-phase, 220/240 VAC power source. Split phase

AC power sources will not work.

Color codes for the AC line cord supplied are as follows.

Table 2. Color codes for supplied AC line cord.

Color Code

Brown

Blue

Green/Yellow

Line function

AC line HOT

AC line NEUTRAL

AC line GROUND (earth)



Environmental conditions

• The unit has been tested for use up to 2,000 m (6,500 ft.).

• Only operate the tester in temperatures ranging from 5 to 40° C (41 to 104° F).

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

31° C (88° F), decreasing linearly to 50% relative humidity at 40° C (104° F). This unit is intended for Installation Category II in a Pollution Degree II environment.

Power pack lifting and shipping

Lifting the instrument

CAUTION

Lift the unit using two 3.6 m (12 ft.) lifting 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 before lifting the power pack.

Figure 5. Properly lifting the unit using straps; example of strap placement only.

CAUTION

The power pack is shipped as indicated by the shipping labels. Inspect the units after shipping and notify carrier immediately if damaged is found.

Confirm that the back panel of the power pack lists the Baker AWA-IV serial number before connecting to the power pack.



Operating and shipping positions

The power pack, when equipped with the Test Select switch option, is not rated for operation in any position other than vertically, 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 instrument is shipped in the upright position.


3 Database management and maintenance

Database management

Database management is a vital component of a good predictive maintenance testing program. Developing best practices for collecting meaningful data, organizing the data collected, and ensuring that users can easily access data contributes to optimal database management.

To support this effort, the software features database management tools that facilitate data organization. Identifiers help clarify the location of specific motors, and allowing the use of multiple databases supports any organization of data storage.

Consequences of not organizing data

Because the Baker AWA-IV can be configured to store every test it performs, we recommend that you establish a structure that everyone performing tests will follow.

Consider the following example. A maintenance program is established to test motors at seven production 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 wants to see all the test data. When the project supervisor looks at the data, he finds nearly 7000 tests—all in one large database, and in a random order.

The manager spends a lot of time looking for the last test performed, but eventually gives up.

Upon investigation, the manager finds that each of the technicians using the equipment had entered data based on what made sense to them at the time. Because of the disorganization, important test data has been lost, or at best is difficult to locate.

The analyzer’s database structure is designed to facilitate data organization and to be flexible enough to allow you to uniquely plan for specific needs. The Motor ID, two location fields, and multi-database support are tools that you can use to organize data to promote data collection and storage best practices, and ensure that valuable data is properly stored and easily retrieved.

Database management and maintenance

Starting the software

To start the analyzer, locate and double-click the Baker AWA-IV icon on the Windows desktop. The software will start and present a window with two options: Create a new database, or Open an existing database.

Figure 6. Opening software from the desktop.

Creating a new database

There are three ways to create a 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 clicking on New from the File menu.

3) Alternatively, you can click on the New database icon in the toolbar.

Whichever method you choose, the same Create New Database window will appear.

12

Figure 7. Creating a new database.



4) The AWAData40 folder is the default folder. Navigate to another folder if you prefer and enter the name of the new database in the box next to the file name.

5) Save as type will always be AWA/MTA Database (* .mdb).

6) Click on the Save button. A database will be created and opened that has one default motor and the default Test IDs. At this point, begin entering new motors using the Data tab Nameplate view.

Opening an existing database

There are three ways to open an existing database:

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 on the Open database icon in the toolbar.

Figure 8. Selecting an existing database.

4) A Select Baker AWA-IV Database window appears to help you locate and select the desired database. It will default to the folder that has been selected in View-

Options-File Locations menu item.

5) Select a database (.mdb) then click the Open button, or double-click on the desired database.



Using multiple databases

The analyzer software supports the use of multiple databases. This feature gives you options for storing your test data. For example, you can split data between different databases, or you can direct different locations to store data locally while using a central location for archiving and backup storage. You can also group motors using the most beneficial strategy that suits your organization and its needs. Consider a few examples.

• A motor shop might want to use different databases for each customer.

• A preventive maintenance department could use a different database 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 main database.

Figure 9. Opening an existing database.

NOTICE

It is important to establish best practices for database organization early, and to maintain adherence to your practices to avoid loss of data or data duplication.

Manipulation of the database may be useful for management and auditing purposes, but you should proceed with caution.

Do not delete records associated with Motor IDs.

Always back up a database before deleting records or manipulating the database in any way.



Data Transfer feature

The data transfer feature offers a way to transfer motor and test information from one database (source) to a second database (destination). The transferred information is not deleted from the source database, but rather copied to the destination database. Data transfer can be used to combine two existing databases into one centrally located database.

It can also be used to re-organize existing databases into more convenient groupings. When motor data or Test IDs need to be moved, the data transfer feature provides this functionality.

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 databases must exist before beginning the transfer. If the transfer will be to a new destination database, it will need to be created before beginning the data transfer.

1) To create a new database, select the File --> New menu item or click on the New icon in the toolbar.

2) To start the data transfer feature, click on Database in the main menu then Data

Transfer , or click on the Data Transfer icon in the toolbar.

Figure 10. Data transfer buttons.



3) The software will open a Source window and will default to the folder in which the currently open database resides. For example, in the graphic below the example database is open in the main program; so when the Data Transfer button is clicked, the Source window defaults to the AWAData40 folder with the Example.mdb

for 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 button. The Data Transfer window appears with the source database opened on the left side. This is the same

Motor ID tree structure as used elsewhere in the software.

16

Figure 12. Data transfer source selection.



5) Click on the destination database Browse button to locate the destination database.

A Destination File Open dialog box appears and will default to the same folder used to open the source database.

6) Choose a destination database to open then click on the Open button. The Data

Transfer window returns with both databases open.

Figure 13. Data Transfer destination database section.

7) If either database is not the one you need, click on the Browse button next to the database you want to change, then locate and select the database needed.

8) When the proper source and destination databases have been opened, the Add All and Add buttons are enabled.

9) Highlight the data you want to transfer then click the Add button to move the data to the Transfer List . Alternatively, you can double-click on a motor and it will automatically be added.

10) If you want to add all data, click 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, remove them by selecting the motor(s) and clicking the Remove button.

12) When the Transfer List is finalized, click the Transfer button. The software runs through the Transfer List adding the motor (nameplate) information if the motor does not exist in the destination database. If the motor does exist, no motor information will be added unless you check the Update the nameplate box.

13) If this box is checked, all nameplate data will be transferred during the process, overwriting any existing information currently stored in the destination database.

14) Similarly, the Update Test IDs check box allows you to update (overwrite) and Test

ID data for existing motors in the destination database with those associated with the motor test results selected for transfer.



15) As the test results are transferred, any TestID that is used will be remembered for the end step. At that end step, all such referenced TestIDs (for any transferred test results) will be transferred across.

16) The software adds test records that do not exist in the destination database. It compares the time/date stamps with existing test result records; if the source time/ date equals a test result record in the destination database, it does not transfer the record. If the software does not find a matching time/date, it adds the source test result record to the destination database.

17) The software creates a log during the data transfer process. Information logged includes source/destination database names, Motors IDs added, the number of records updated, and Test ID data updates (if update Test IDs box is checked). If the transfer encounters problems, it logs the Motors ID and reason the transfer failed.

You can print this log by clicking on the Print Log 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 data” section above. The source and destination databases must be open before a transfer can be performed. When both databases are open, the Transfer Test IDs button will be enabled. Click on this button to open the Transfer

Test ID’s window.

Figure 14. Transfer test IDs.

The window displays all Test IDs in the source database, along with the Test IDs currently found in the destination database. Choose the source Test IDs to transfer by highlighting them. To select multiple IDs, use the Shift and Ctrl keys on your keyboard while clicking on the Test IDs.

With the desired Test IDs highlighted, click on the Transfer button to start the transfer.

The software will transfer (copy) the requested Test IDs to the destination database. If a Test

ID exists in the destination database, it will overwritten with the parameters assigned to the selected TestID.



As in the motor and test result record transfer, the application writes to the Transfer Log, recording what action has been taken. When finished transferring Test IDs, click on the Close button to return to the Data Transfer window.

Archiving a database

The Archive feature provides another tool to help you move data. The tool helps you back up and move whole databases from one computer to another. In comparison, the Data

Transfer tool moves motor/test information from one database to another.

NOTICE

It is important to retain a current backup copy of database(s) on some persistent storage medium such as an external hard drive, flash drive, or a backed 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. If the archive option is used to copy a database, use the Restore option (discussed in the next section) to extract the database from the storage device back to the source.

To archive a database, it must be opened in the software.

1) Click on Database in the main menu then Archive .

2) The New Archive window appears showing the default folder. The Save in folder defaults to the path specified via the View menu--> Options --> File Locations .

3) Accept the default or browse to the folder where the archived file should be stored.

Figure 16. New archive.



The default name of the archived (bak) file will be a combination of the database name and the time/date of the archive. For example, if the database name is Example.mdb then the archived file name will be Example_YYYYMMDDHHMMSS.bak. The date/time format is

YYYYMMDDHHMMSS and indicates the year/month/day/hour/minute/second when the file was archived.

When the archive is finished, a message similar to the following will be displayed:

Figure 17. Archive complete.

NOTICE

Ensure that you make note of the location of the archived 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 minimize the space needed for storage. File formats such as .cab and .zip were common.

Support has been maintained for .zip and .cab files if an older archive using these formats needs to be restored. For such restorations, WinZIP will need to be installed on the system.

To view archived data with the software, the database must be restored first.

1) Click on Database then Restore .

20

Figure 18. Restore database menu item.



2) The Select Archived Database window appears. Select the database file that you want to restore and open it.

Figure 19. Data transfer buttons.

3) After choosing the archived database 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, click the OK button.

Figure 20. Locate the proper folder needed.



The software will extract the archived file. If a database with the same name exists the user will be prompted with the following.

Figure 21. Confirm file overwrite.

Overwrite the existing database by clicking on Yes or Yes to All . Click Cancel if the database should 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 named database.

After the archived database is extracted, the software will return to the main screen. Click on

File-->Open to open the newly-restored database.


4 Baker AWA-IV instrument overview

Baker AWA-IV 2 kV/4 kV model front panel

All Baker AWA-IV series analyzers feature a large eight-inch touch screen with a graphical user interface. The interface features a logical layout of large touch icons that improve ease of use. Each tester’s voltage capacity 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 monitor (not included) for easier viewing of test results.

USB ports

Industry standard USB ports are accessible from the front panel for connections to a printing device, and data storage and retrieval devices.

Ethernet connector

The tester can be connected to a network via the ethernet connector.

Baker AWA-IV instrument overview

Emergency power shut-off

This large, highly visible red button is easily pressed on the front panel for emergency shutdowns. It cuts all power to the unit swiftly and safely.

Resistance leads

Three test leads (red) and a ground lead (black) are provided for motor test connections.

Both sides of the connection clips must be in contact with the terminal of the motor being measured.

High-voltage test leads

The Baker AWA-IV uses high-voltage test leads for surge, Baker ZTX, 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 or counterclockwise to decrease the voltage. The rate of voltage increase or decrease is set via the touch screen interface. Do not force the knob; turning the knob harder does not cause voltage to ramp any quicker and may damage the instrument.

Baker AWA-IV 6 kV/12 kV model front panel

Figure 23. Front panel controls for Baker AWA-IV 6 kV and 12 kV models.



CAUTION

It is important to note that the clips have exposed metal areas. Do not touch the clips while tests are running. Always exercise care to ensure the clips are not placed in proximity to the frame or ground potential.

Baker AWA-IV 6 kV model distinctions

The AWA-IV 6 KV model differs from the AWA-IV 12 kV with respect to test leads and procedures for use.

The AWA-IV 6 kV analyzer uses only one set of leads for both high- and low-voltage testing; it does not include a separate set of low-voltage test leads (shown as “resistance test leads” in figure 23).

Setting up the Baker AWA-IV tester

Selecting an optimal environment

• The Baker AWA-IV requires adequate ventilation. Place the analyzer where air can freely circulate around it.

• Avoid locations in direct sun or near heat sources.

• Do not stack objects on or near the analyzer.

• To prevent shock hazard, do not expose the analyzer to rain, snow, or moisture.

• Avoid locations with high levels of dirt 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 cable into the line connector on the left side of the analyzer and plug the other end into a grounded wall socket. The analyzer will operate between 85–264 VAC 50/60Hz.

3) Locate the keyboard/mouse USB unit. Plug the unit into one of the USB ports.

4) If an external storage device will be used, plug it into one of the USB ports.

5) Turn the power switch to the On position.

6) As the analyzer powers up, various BIOS messages will appear on the screen.

7) The analyzer will automatically log in to the software with the associated serial number information.

NOTE

An administrator can change this to log into the Windows desktop; however, we recommend that you do not change it. If passwords are changed and the instrument is returned for service without the passwords, the instruments hard drive will be reformatted and all user-saved data may be lost.



Connecting test leads to motor under test

How test leads are connected to the motor under test will vary depending on the specific

AWA-IV model you will be using and the type of test you will be conducting. For example, the

AWA-IV 12 kV model has an extra set of low-voltage test leads used during resistance testing, while other models only have the high-voltage test leads.

In most applications, test lead 1 is connected to phase A of the motor under test, lead 2 to phase B, and lead 3 to phase C. In single phase or two-lead applications, only one red lead

(typically lead 1) would be used while the other two leads are left disconnected.

Ensure that you understand how leads should be connected for your application

NOTE

AWA test leads use Kelvin (4-wire) resistance measurement that uses an active current source, reduces the effect of lead resistance, and gives an accurate resistance measurement. Each side of a lead clip contributes to the measurement process; one is the supply and the other 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 for your application before energizing the tester.

Ensure that all safety precautions are taken to keep yourself and others safe, and to ensure proper operation of the equipment and to avoid damaging the equipment or the unit under test.

Configuring a printer

The Baker AWA-IV comes with a set of printer drivers installed. More printer drivers may be added if necessary. Connect the analyzer to the printer then run the configuration process via the Windows Control Panel application. Ensure that the proper printer driver is selected during the configuration process.

Using the footswitch

On the rear of the analyzer, a four-pin connector is available to plug in a footswitch to operate the analyzer for armature span testing. The footswitch allows you to continue testing the entire armature easily and quickly.

The footswitch option is not available for AWA-IV 6kV or 12kV models.


5 Baker AWA-IV software overview

The Baker AWA-IV software automatically performs pre-configured tests on pre-configured motors. Pre-configured tests are identified by Test IDs. Pre-configured motors are identified by Motor IDs.

Motor IDs are stored in the Baker AWA-IV’s database along with the Test ID to be used when testing that motor. Additional information about the motor such as manufacturer, serial number, horsepower rating, frame size, speed, operating voltage, and current are also stored in the Motor ID. New motors can be entered into the database or existing motors can be edited, corrected, or updated.

The 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 Test IDs.

The software includes predefined Test IDs for several different machines. Usually, the most important parts of a Test ID are the test voltages. Therefore, a Test ID is often named after the operating voltage of the motor. Several motors can share a single Test ID. For example, all 480-volt motors can use the same Test ID.

Starting the software

To start the Baker AWA-IV, locate and double click the Baker AWA-IV icon on the Windows desktop. The Baker AWA-IV software will start and present a window with two options: create a new database or open an existing database.

Figure 24. Opening software from the desktop.

Baker AWA-IV software overview

Creating a new database

There are three ways to create a new database: click on the radio button upon entering the software, click on File --> New while using the software, or click on the new database icon while using the software.

1) To create a new database when starting the software, click on the Create a New

Database radio button. Type the name of the database and click Save .

2) If the software is already running, you can create a new database by 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 as type folder is the default folder. Navigate to another folder if you prefer and enter the name of the new database in the box next to the file name.

5) Click on the Save button. A database will be created and opened that has one default motor and the default Test IDs. At this point begin entering new motors using the Data Nameplate tab.



Opening an existing database

There are three ways to open an existing database: click on the Open an existing database radio button upon entering the software, click on File --> Open while using the software, or click on the open database icon while using the software.

1) To open a database after the software is running, click on 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 default to the folder that has been selected in View-

Options-File Locations menu item.

3) Select a database (.mdb) then click the Open button or double clicking on the desired database.

Figure 26. Selecting an existing database.



Using version 4 software for the first time

The first time the Baker AWA-IV software is used, the Enter Test Equipment Information window will appear. Select the analyzer type, serial number (found on a sticker on back of unit), and customer’s analyzer ID (can be an asset ID). If the software is being installed on a desktop computer, all other fields will be gray.

This information will be used to track each data record and to identify which Baker AWA-IV analyzer acquired the given record. The 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 in the Tests tab.

Figure 27. Enter Test Equipment Information window.

NOTE

Test results from a converted database (databases from a pre-4.0 version) will not have this information. Converted records will contain the type of Baker AWA-IV converted. Subsequent test results will be stamped with machine information, which can be examined in the Application view at the bottom of the pane.



Main window

After selecting or creating a database, the Baker AWA-IV software Main window appears:

Figure 28. Selected database.

To view test results for a given motor or to perform a test on a motor, you must first select the desired motor from the database. 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. The right pane contains three more tabs— Data , Tests , and Trending —that help you view test data, performance of set tests, and trending mechanisms.



The Main window includes several tools that help you navigate the user interface and access the software features and functions. The tools include the Main menu , the Toolbar , and the

Tabs mentioned above.

Figure 29. Main window tools.

Main menu

The Main menu contains six menus that provide access to features and functions organized by the categories 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 use during your session. Databases that are open are listed just above the

Exit item.

Clicking on Exit closes the application.

The Print menu item provides access to printing features by opening the Report Generator.

32

Figure 30. File menu.



View menu

The View menu allows you to specify whether the Toolbar and Status Bar will be displayed in your view of the user interface. A check mark next to an item indicates that the feature will be displayed.

The Options item drops down a sub-menu that provides access to additional features.

Clicking on the File Locations item opens a dialog box that helps you identify where specific file types used by the system are stored. You can also use this dialog box to modify locations if needed.

Clicking on the Changable Labels item opens a dialog box so you can rename the motor location fields. Label one default is “Location,” label two default is “Building.”

Clicking on the Enable Voltage Class item toggles the 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 to a new Motor ID.

Enabling voltage class restricts the Test IDs available to a motor to the Test IDs associated with the voltage class, ensuring that Test IDs using higher voltages cannot be assigned to the motor.

Clicking on the Allow Duplicate Motor ID’s item allows the system to create motor IDs that are identical. For example, if you have two identical motors that both drive cooling fans, you might want to give them the same Motor ID. Notes within the Motor ID, or the placement of the Motor ID in the “building” and “location” folders can be used to uniquely identify each motor.

Figure 31. View menu.



Database menu

The Database menu provides access to functions used to maintain and manipulate database files. The data transfer, archive, and restore features are described later in sections relevant to their specific context.

Clicking on Locate on Disk opens a window that shows you the current 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 Window menu provides you with functions for selecting which database to use (if several are open) along with options for displaying windows within your screen.

Figure 33. Window menu.



Tools menu

The Tools menu provides access to other basic tools including WordPad, MS Paint, and a web archive file viewer. The Baker AWA-IV generates reports in a mhtml format (optionally); these files can be viewed using the web archive file viewer. WordPad can be used to view files output in MS Word format, and the MS Paint program is handy for annotating screen captures.

Figure 34. Tools menu.

Capturing screens

You can capture screens as needed if you would like to include specific views in reports 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 MS Paint .

Use the following hotkeys during the screen capture process:

• Print Screen captures whole screen .

• CTRL+ALT+Print Screen captures the focus window.

• CTRL+ V pastes the captured screen in MS Paint.

Help menu

The Help menu provides information about the software version and the tester. It also provides access to the current user manual, which is available online.

Figure 35. Help menu.



Toolbar

The Toolbar contains several icons that provide shortcut access to several features that can also be accessed from the Main menu. From left to right the icons (and their features) include New, Open, Print, Transfer 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 with the number of test records currently stored in the database for the selected device/motor.

Figure 36. Toolbar.



Tabs

The left side of the Main window is used to navigate through the motors within the opened database. Three tabs help you locate and select motors for testing.

The Explore tab displays the motor locations in a three-level view called the Motor Tree .

The Motor ID tab gives you an alphabetical list of Motor IDs. You can type the first few characters of the Motor ID into the blank field above the list to locate a specific motor.

The Route tab provides predefined lists of motors used to locate a subject motor. The Route tab is similar to a route often used in the predictive maintenance business.

Explore tab

The Explore tab uses a tree structure to 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 Building are the default tree labels, but these labels can be changed to suit your situation and best practices.

The lowest level is the Motor ID. In the example above, the selected Motor ID is BD#3. The motor is physically located at the North Platte plant, Barrier Dam. By clicking on Motor ID, a motor and its associated data is loaded from the database into the related tab fields on the right side of the window. It becomes the current motor. Expand a motor location by clicking on the plus sign or contract a location by clicking on the minus sign.



Motor ID tab

The Motor ID tab alphabetically lists all motors currently stored in the database. When you double-click on a motor in the list, the list item is highlighted and the Motor ID appears in the field found just above the list. The motor’s information is also loaded into the Main Display

Area to the right.

Figure 38. Motor ID tab.

Locate a Motor ID two ways within this tab: using the Motor ID search field at the top of the list, or scrolling through the list until you spot the motor you need.

To use the Motor ID search field, type the 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 characters. For example, if the letters Cmp are typed, the Cmprsr32-45A Motor ID would be highlighted.

Whichever method you choose, when you find the Motor ID you are looking for, double click on that Motor ID. Ensure that the Motor ID you want is highlighted and appears in the field just above the list. Using either method, the Motor ID will become the currently selected motor and its information will appear in the Main Display Area.



Route tab

The Route tab allows you build lists of Motor IDs for routing purposes.

Figure 39. Route tab.

As the example above shows, the “Spring Outage” list is selected. This list has four motors associated with it. Using such lists eliminates the need to search the entire database for these four motors to be tested during the spring outage.

This tab also allows editing and printing of these routes. Click on the Edit Route button to open the Route Editor dialog box, which allows you to Add, Rename, and Delete routes. You can also add, remove, and change the Motor ID list order.

Adding a route

1) To add a new route, click on the Add button at the top of the window. The Routes field will be blank so you can enter a new Route 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 the <<Add button. The

Motor ID will be moved from the Available Motors list to the Route Motors list.

Continue adding motors as needed. Use CTRL or Shift keys on the keyboard to select multiple motors.

3) When you have finished, click on the Save button at the top of the window. Click

Close when you have finished creating the new route.

Renaming a route

1) Select the Route you want to rename from the route list and click Edit Route .

2) In the Route Editor dialog, click on the Rename button.

3) The Route ID will be highlighted. Edit the ID as needed then click the Save button.

Click Close to return to the Route tab.



Deleting a route

1) Select the Route ID you want to delete from the Routes list. Click Edit Route then in the Route Editor ensure that the correct route is selected.

2) Click on the Delete button. A confirmation dialog appears to ensure that you are deleting the correct route.

NOTE

Deleting a route does not delete the Motor IDs from the database.

Editing motor IDs on an existing route

1) Use the Route ID combo box to select the route you want to edit.

2) The Motor IDs associated with that route will appear in the Route Motors list.

3) All Motor IDs not on the route will appear in the Available Motors list.

4) To add Motor IDs, select the Motor IDs 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 IDs from the route, select the Motor IDs from the Route

Motors list then click on the Remove>> button. The Motor IDs will be removed from the Route Motor list and returned to the Available Motors list.

6) To change the order of the Motor IDs in the Route Motors list, select the motor or group of motors to move and click on the Move Up or Move Down buttons found just below the list.

7) When you have finished editing a route, click on the Save List button to save your changes.

8) Click on Close to return to the Route tab in the main window.



Modifying the display of lists in the Motor ID and Route tabs

The information presented in the motor lists within the Motor ID and Route tabs can be customized by a qualified system administrator modifying the AWA.INI

file.

In the following example, the Route tab list shows that the modification includes listing the

Plant name, Building (BLDG/Unit), and the Motor ID. Using the scroll bar at the bottom of the list shows all the information presented and formatted as defined by the AWA.INI file modification.

The same or different 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 Trending tabs.

NOTICE

Only a qualified system administrator should make changes to the AWA.INI file. Errors in formatting or syntax, accidental deletions or omissions, or other mistakes can cause improper software behavior.

Best practices are recommended, including backing up original AWA.

INI files to provide a reset point if needed. For more information on this process, refer to the AWA Database Tool Administrator Guide.



Viewing test data

The right pane of the software has three tabs at the top of the window— Data , Tests , and

Trending. Respectively, these tabs help you view results 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 window features Data , Tests , and Trending tabs.



Using the Data tab

The Data tab contains two sections, one above the other. The top section shows the date and time for the test result data, and whether the motor passed the specific 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 changes depending on which bottom tab is selected.

Figure 42. Data tab sections.



Motor location fields

The first two fields in the bottom section of the Data tab are used to help locate a motor within the database. These fields have the default field names “Location” and “Building.” If these are not the best labels for your situation or environment, you can change them.

To change location labels, click on the View menu then Options then Changable Labels .

Consider the example that a motor maintenance program has several plants. The labels of the location fields could be renamed to something like “Plant” and “Unit.” The location data is used with the Motor ID to create the nameplate record and to make up the tree structure of the Explore tab.

In the example Explore tab shown in the next section, motors have been organized by location in Plants and Units: North Platte and South Branch are Plants and Unit 23, Unit45A,

Unit 17C are all units.

Figure 43. Changeable labels.

Some organizations use three fields to describe motor locations; some refer to them as functional locations. For these users, a third location field is made available by assigning a label name to the field, which will then appear within the Data tab main display area just below labels 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 Description field provided at the bottom of the display area.

Motor ID field

The records stored by the Baker AWA-IV are hierarchically linked to each other. The Motor

ID field serves as the primary key for linking associated records. The Motor ID is the primary means of locating and interacting with a motor’s data. Therefore, it is important to develop a naming scheme that will facilitate locating and retrieving information.

Consider the common case in which a plant has duplicate processes, with identically named motors in each process. This can cause confusion, because the motors have the same Motor

ID, but are in different locations. Take steps at the start to ensure that Motor IDs are unique.

For example, if two identical intake pumps are present in duplicate processes, database management will be easier if these two motors can be uniquely identified. One way to solve this problem is to include the process ID in the motor ID. For example, the motor ID for process 1 could be “Intake Pump P1” and the Motor ID for process 2 could be “Intake Pump

P2.”



Data tab—Nameplate view

The Nameplate view contains the nameplate data for each motor in the database. The first field is Motor ID , which is used by the software to uniquely identify the motor. Values must be entered in the Motor ID and the two motor location fields.

The labels for the location fields are user definable. In the example below, the labels are

Plant and Unit . The default values are Location and Building . If you need to change the field labels, click on the View menu then Options then Changable Labels .

The location and Motor ID fields are required because they are used in the Explore tab to help locate motors. If the enable voltage class feature is used, the Volts 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

Nameplate view are optional.

NOTE

Many customers have found that filling in all nameplate fields greatly helps with preventive maintenance programs by providing one place where their plant’s motor data is kept. Additionally, motor shop customers often discover that recording complete nameplate information is required when working with their customers’ motors. The information can also help with troubleshooting and support.

Figure 44. Data tab, nameplate view.

The Nameplate view is also used to add new motors, update existing motors, and delete unneeded motors from the database.



Adding a new motor

1) Click on the Add button. The Motor ID and SN (serial number) fields will be blanked out.

2) If needed, click on the Clear button to clear all fields.

3) The Location fields ( Plant and Unit in this example) and Motor ID are required.

Values entered cannot begin with a space. If more than one location exists, click on the down arrow of the location boxes. You can enter a new Plant location simply by typing the new name in the field.

Figure 45. Adding a new motor ID. Required fields appear in blue in this example.

4) If voltage class restriction is enabled (via the View menu Options and Enable

Voltage Class is checked), entering a value in the Volts Oper field will also be required. Entering information in other fields is highly recommended for tracking and other purposes, but is not required. When you have finished entering your values, click on the Save button.

5) Enter the Test ID to 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 added.

Updating an existing motor’s nameplate information

1) Select the desired Motor ID then move the cursor to the field(s) you need to update and make your changes. The Save button will be enabled as soon as changes are started.

2) When finished, click on the Save button and your changes will be committed to the database. If the changes are not needed, click on the Reset button. All fields will be reset and no changes will be committed to the database.

Deleting an existing motor from the database

1) Select the desired Motor ID then click on the Del (delete) button.

2) A dialog box appears to confirm that you want to delete the selected Motor ID, and all of its test results. If you are sure that you want to delete the Motor ID, click Yes.

The motor and all of its test results will be deleted.



Data tab—Application view

The Application view provides a place to enter data about a particular test. Information such as who did the test, who the test was done for, which MCC the test was performed from, and a general memo can all be entered in their respective fields when the test is conducted or at a later date. The general memo field is a good place to put information such as humidity, noticeable vibration of the motor 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 test.

You can use this view to add new application records (which add an empty test record), update existing information, and delete test results.

To change the test result being displayed, click on the date/time in the top section of the Data tab. The Application view will then display the selected date/time’s information.



Test Params feature

The Data tab, Applications view contains a button labeled Test Params that opens a new window similar to the example shown below when clicked.

Figure 47. Test parameters window.

This window provides you with a summary 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 changes to the parameters for any reason before executing the tests, the actual parameters used will be reported in this window.



Data tab—Results Summary view

The Results Summary view displays the test results summarized in a grid or spreadsheet form. Each column represents one test result.

Figure 48. Data tab— Results Summary view example.

The first two rows are used as the heading for each column, displaying the date and time the test was performed. If all tests that were performed passed, the background of the date/time cell will be 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 each test category.

The side-by-side view allows all test results for a motor to be seen in one view, facilitating comparison.

To print a copy of this view, click the right mouse button anywhere on the grid. A dialog box will appear allowing you to choose a printer and parameters for printing the grid.



Data tab—Surge view

The Surge view shows a thumbnail view of the surge waveforms for a particular test along with basic test results and controls for viewing graphs in more details.

Figure 49. Data tab— Surge view showing test results.

Click on the Enlarge button to view the surge waveforms more closely. The waveforms can be viewed in two ways 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 waveforms in comparison.

In enlarged view, you can hold down the left mouse button and drag a box around an area of the screen to zoom in on the area. You can also use your finger to draw the box around the area you want to zoom in on.



In a nested view, waveforms for a single selected lead at the 1/3, 2/3, and full voltage are superimposed.

Additionally, if the test failed, the previous to fail and the failed waveform will be displayed with the failed waveform being drawn in white.

Figure 51. Enlarged Surge view—waveforms nested.

The Surge view not only displays the surge waveforms for all leads, it also renders a view of the pulse-to-pulse (P-P) Error Area Ratio (EAR).

Click on the EAR Graph button to view the pulse-to-pulse EAR graph. The graph displays the

EAR percentage between successive pulses per test lead and the 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 typically set to 10%.

As the voltage is increased, each surge pulse is digitized and compared to the previous pulse.

If the motor under test has weak insulation, the waveform frequency increases and the software will calculate the difference between the previous to failed waveform and the failed waveform. If it calculates a difference greater than the tolerance set, the test will stop and capture the waveform for analysis and reporting.

Figure 52. Pulse-to-pulse EAR example.



Data tab—PI view

Clicking on the PI (Polarization Index) tab displays the PI view, which contains the PI/DA graph and data table.

Figure 53. Data tab, PI view.

The PI graph charts the current vs. time and the MegOhm reading vs. time. Under the PI graph are selected data points used in the graph. On the right side of the graph you will see data for PASS/FAIL, test voltage, 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 element from the display.

In the small graphic display area, you can hold down the left mouse button and drag a box around an area of the screen to zoom in on the area. You can also use your finger to draw the box around the area you want to zoom in on.



Data tab—Step/Ramp-Voltage view

Clicking on the Step/Ramp-Voltage tab displays the Step Voltage test data in both graphical and tabular form. The graph defaults to plotting current vs. voltage.

The red triangles indicate the current level at the end of each step.

Clicking on the Current vs. Voltage or Current/Voltage vs. Time radio buttons determines 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.

Figure 54. Step/ramp Voltage view showing current vs. voltage.

NOTE

The large swings of the red real-time current lines show the motor’s charging current while ramping up voltage. These large swings do not indicate an insulation problem.



Most concern is typically given to the current at the end of the voltage step. End-of-step currents should be linear. If they are not, an insulation problem is often indicated. The data in the table below the graph shows the test time per step, the voltage of each step, the measured end-point current, 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 the screen to zoom in on the area. You can also use your finger to draw the box around the area you want to zoom in on.

Press the space bar on the keyboard to zoom back out to full view.



Using the Tests tab

Clicking on the Tests tab changes the display area in the right side of the Main window as shown in the example below. This is the main testing window. Each test the analyzer performs is indicated by several columns of buttons that show the test status.

In the left-most column are On/Off buttons that show if a test is active. Click on the related button to turn each test on or off.

Click the buttons in the center column to execute the particular test. This is considered semiautomatic testing.

Figure 56. Test view.

Use the test configuration buttons to open a new window used to configure each test. The button labels indicate how each test is set up, how many leads will be used, the test voltage applied, and so on. Each test’s configuration window is described below.

A fourth shaded column appears at the end of testing. Green indicates that the test passed; red that it failed. A red indicator also displays the reason the test failed.

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 check box. You will be prompted for a password. If this is the first time you are editing a Test ID since the Baker AWA-IV software’s installation, click on the Change Password button and enter the password in its field.

Click on the Set Password button.

If this is not the first time you are editing a Test ID, simply enter the password and click OK.

Three new buttons will appear below the Test ID. Use the Save button to save changes you make to the selected Test ID. Use the Add button to add a new blank Test ID or to copy a selected Test ID. Use the Delete button to delete the selected Test ID. When you are finished editing Test IDs, or if you decide not to edit, uncheck the Edit Test ID box to disable Test ID editing.

NOTE

Leaving the Tests view will also disable the editing of Test IDs and all changes will be lost if they have not been saved.



Test configuration

Three setup windows are used to configure tests: Temperature/Resistance, DC Tests, and

Surge Tests. Each window is described below.

Settings and parameters specified in the setup windows define the Test ID. If you want to update parameters for all motors using the selected Test ID, check the Edit Test ID box before editing test parameters. You can then save your changes when finished.

Temperature/Resistance test setup window

When one of the temperature or resistance test configuration buttons is clicked, the

Temperature/Resistance Test setup window appears. The resistance and temperature test parameters are combined into one window as shown below.

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 is used to acquire the motor’s temperature (as close as possible to the winding). Some motors may even have temperature detectors installed, but other methods such as scanning guns can be used to acquire the motor (winding) temperature. The temperature collected via the external devices is entered manually in this setup window.

Temperature can be entered in degrees Celsius or Fahrenheit.

The temperature acquired at test time is used during testing to temperature correct coil resistance values per IEEE 118 and insulation resistance values per IEEE 43/95.



Resistance measurements can be influenced by humidity. To enable setting the relative humidity, check the Relative Humidity box then enter the humidity present. Click on Accept to commit the settings. .

The resistance test has several options. The test can be performed on a two-lead device such as a single coil or a three-lead device such as a three-phase motor. The motor may have wye or delta winding configurations. The wye or delta configuration is entered in the nameplate window and is defined here based on that entry.

Figure 58. Resistance enabled.

Resistance values can be automatically acquired by the analyzer, or by some other means and manually entered into the software. The method for entering or obtaining resistance data is described later.

By checking the Delta R (%) box, the resistance values will have their percent spread calculated at the end of the test. If the percent spread is outside the number 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 parameter in the adjacent field.

The temperature the resistance value is corrected to is set to 25o C by default, but it can be changed to another value. IEEE 118 recommends 25o C. The constant used to convert resistances at one temperature to another is known as the IEEE 118 constant and is 234.5 for copper or 224.1 for aluminum.

A motor that does not have a resistance reading within a target resistance range can also fail.

Correct this issue by checking the Target Corrected Resistance box and entering the expected corrected resistance values and tolerances.

NOTE

Only temperature corrected values will be used in determining if values are within tolerance.

At the end of the test, the analyzer compares corrected resistance readings to the target corrected resistance to determine if the motor passes.



The lower portion of the Temperature/ Resistance Test window contains buttons used in manual and semi-automatic testing. It also include three columns that display test results for all testing options. The Delta R average result is also displayed here.

Three columns report measured line-to-line resistance, temperature corrected resistance, and calculated coil resistance values.

As mentioned previously, there are two ways to obtain resistance data. In automatic mode, the analyzer will measure the resistance when you click on the Automatic radio button. The second way is to manually measure the leads using a precision resistance bridge then directly entering the values into the corresponding Measured L-L fields.

NOTE

A precision resistance bridge is a typical example of a device that is sensitive enough to collect accurate data to use in resistance imbalance calculation. It is most important to ensure that the instrument used can give you accuracy that is consistent with the measurement being made and the device being measured.

Figure 59. Test Results section of the Temperature/Resistance Test setup window.

Another key difference between the automatic and manual modes is that the automatic mode will make a resistance measurement per your specifications between a lead with the 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 with a bridge will be between two leads with a third lead allowed to float. Due to this difference, the winding configuration becomes even more important. The Baker AWA-IV software assumes that manually entered data will be made with a two-lead precision bridge and that the third lead is allowed to float. Clearly, a wye motor’s lead-to-lead measurement will be different from a delta lead-to-lead measurement.

Regardless of how the resistance measurements are acquired, after they are obtained the software will calculate the temperature corrected resistances and display them. Additionally, if possible, the analyzer will calculate the individual coil resistances. If not, the software will display a message indicating that a solution to the coil resistance could not be found.

While the Temperature / Resistance window is open, there are several ways to start a resistance test measurement:

1) Click the Test All Leads button. The analyzer then measures each lead’s resistance sequentially (semi-automatic testing).

2) Click one of the lead buttons on the Baker AWA-IV front panel. The analyzer then measures the resistance of the clicked lead only and displays the results (manual testing).



Manually entering resistance measurements

Resistance measurements taken from the motor using a high-precision resistance bridge can be manually entered instead of having the analyzer run an automatic resistance test.

Manually entered data should be line-to-line type measurements.

To enable manual data entry, click one of the manual entry buttons (Lead 1–2 (Ohms) ; then the results section of the Resistance test window enables the Measured L-L column so you can directly enter the lead resistances taken. When you have finished entering data, click the

Accept button.

Wye-wound resistance measurement

Using the NEMA nomenclature for a wye-wound motor, the resistance measurement for lead

1 should be made between terminals 1 and 2 with terminal 3 left floating. This measurement will consist of coils 1–4 in series with coils 2–5. Likewise, the lead 2 measurement should be made between terminals 2 and 3 with terminal 1 left floating. The lead 3 measurement should be made between terminals 3 and 1 with terminal 2 left floating.

Delta-wound resistance measurement

Using the NEMA nomenclature for a delta-wound motor, the lead resistance measurement should be made between terminals 1–6 and 2-4. This 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 should be made between terminals 3–5 and terminals 1–6.

After entering all data and clicking the Accept button, the measurements will be temperature corrected and displayed in the Temp Corrected column. The coil resistances will also be calculated for the individual coils and displayed in the Calculated Coil R column.

Coil resistances

As discussed above, the resistance measurements made by the Baker AWA-IV are a userconfigured series or a parallel combination of coils. At the end of a resistance test, the analyzer will calculate and display the coil resistances. If a temperature has been entered, it will report those values. These values are found in the right-hand column of numbers in the

Resistance window. The calculation involves numerically solving for the coil resistances given the type of winding (wye or delta) and the measured balance values.

Under some circumstances, the algorithm may fail because it cannot return a valid result based on the values entered manually. In such cases, the analyzer will indicate that it cannot find a solution given the balance resistance values.



DC Tests setup window

The DC Tests window is displayed when one of the MegOhm, PI/DA, or HiPot test configuration buttons is clicked in the Tests view.

Figure 60. DC tests setup window.

The MegOhm is the first test to be run, followed immediately by a PI or DA test, and then a

HiPot type test. There are two dropdown lists for PI/DA and HiPot type tests. The PI/DA list includes all options for PI or DA testing. The HiPot tests list includes Ramp-Voltage and

Step-Voltage tests in addition to the standard HiPot test. Setup parameters are made for the specific test type chosen from each list. Test voltages, minimum MegOhm readings, voltage ramp rate, test times, current trip settings, discharge times, minimum PI values and more are all entered in the fields within each test type column.

The PI test has two extra options: 1) default to the Dielectric Absorption if the IR=5000MΩ at

1 minute and 2) the Dielectric Absorption test only. The PI test has many 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, all selected tests can be run by clicking the Run Selected Tests button.

You can also specify temperature correction values and insulation type using the dropdown list and field found below the Run Selected Tests button. After you select an insulation type from the list, the Temp Correction field is enabled so you can enter the appropriate value.

At the bottom of this section is the Touch Screen E-Stop Enabled checkbox. If you check the box, touching the screen during testing will result in an automatic stop in testing, which will be recorded as a user abort.

The right side of the window displays the real-time voltage, current, and insulation resistance readings collected during the MegOhm and HiPot tests. The voltage and current are displayed as slider bars. Below the slider bars are real-time voltage and current numerical outputs.



Ramp voltage test

The ramp voltage test is mostly used when testing generators. It gives information on the contamination level with the winding. The ramp voltage test is performed for a predetermined length of time at a specific voltage level. The voltage increases linearly on a specific time scale.

As the test is operating, the key is to watch the 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 of this test. In the illustration, the unstable line suddenly increases in voltage and current. If this occurs, it could indicate an imminent overcurrent trip and a problem within the winding.

Figure 61. Evaluating charging current during ramping.



Step Voltage test

The Step Voltage test, also called a step test, is described in detail in IEEE 95. Clicking on the dropdown arrow for HiPot tests reveals the Step Voltage test. Clicking on the Step Voltage test menu item will start the Configuration Wizard used to set up the test.

Figure 62. Step voltage Config Wizard—step 1.

Fill in the appropriate information for the steps needed. Make sure the 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 test runs and will display a real-time graph of the voltage and current collected during the test. After this test has been set up, it can be edited prior to running. Click on Config in the DC Tests setup window and the second step page appears.

Figure 63. Step voltage Config Wizard—step 2.



Surge test setup window

The Surge test setup window, shown in the example below, appears when you click on the

Surge test configuration button, at the end of the Surge row in the Tests tab.

Figure 64. Surge test setup window.

In the upper left corner of the window the surge voltage, voltage ramp rate, and the number of surge pulses are entered in their respective fields.

We recommend that the surge voltage be 2V+1000. The voltage ramp rate controls the rate at which the voltage increases during the test and is set to a default rate of 25 volts.

Use the Surge Pulses field to define the number of pulses applied to the winding after the full test voltage is reached.

The Volts/Div and µSeconds/Div fields are related to the x- and y-axis of the surge waveform graph located in the middle of the window. The Volts/Div field is set to Auto by default, but you can manually enter a specific value if you prefer. This field determines the y-axis scale on the surge waveform graph. The µSecond/Div (x-axis) field is also set to Auto by default to capture the waveform in time, or you can manually enter a specific setting if preferred.

The top center of the window includes a series of check boxes that determine Pass/Fail criteria for the Surge test. The L-L EAR (%) check box sets the maximum Lead-to-Lead Error

Area Ratio (EAR) allowed between the different leads. This is usually set to 10%; however, some people have found settings as low as 4% to be useful.

NOTE

This option should not be set if testing a motor with a rotor installed. If it is absolutely necessary to use the L-L EAR with the rotor installed, increase the tolerance to avoid nuisance trips. The increase in EAR tolerance with installed rotors makes the use of this feature a poor detector of a turn-to-turn insulation problem.



Use the P-P EAR (%) field to set the maximum Pulse-to-Pulse Error Area Ratio allowed for the test.

Figure 65. Pass/Fail tolerances.

The Zero Crossing (%) option determines how much a waveform must shift to the left during the Surge test before crossing the zero reference line. A turn-to-turn fault is identified by a sudden jump to the left of the surge waveform. If a waveform jumps more than the percentage indicated, the motor will fail the Surge test.

The remaining three columns (L1, L2, and L3) show real-time numbers for the specific lead while the test is running. These numbers will become visible during the test. The numerator represents the last P-P EAR taken for the test (for most passing tests, this will likely be 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 previously stored reference test. If the field is disabled as shown in this example, a reference waveform has not been set. See “Creating a Surge test reference” later in this chapter for details.

The four buttons on the right side of the window will run a Surge test when clicked. Clicking on the Lead 1 button starts a manual Surge test on lead 1 only; likewise for the Lead 2 and

Lead 3 buttons.

Clicking on the All Leads button starts a semi-automatic three-lead Surge test. A Surge test can also be started by clicking one of the test buttons on the front panel of the analyzer.

Figure 66. Run surge buttons.



The final voltage reached for each lead tested is displayed in the text boxes to the right of the graph area. The EAR values shown correspond to the measured L-L EAR between the three leads during the test.

Figure 67. Final peak voltages and EAR values.

E bar graph

The surge waveform graph is shown in the graphic below. The vertical (y-axis) displays the voltage while the horizontal (x-axis) displays time. The surge waveform is a plot of the voltage across a coil versus time. On the right side of the graph is a bar graph with an E label at the top. This bar graph will 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 obtain the surge waveform (when the foot pedal option is used). Low impedance coils (those with only a few turns) require more energy in the surge pulse to develop a given voltage than a higher turn count coil. The E bar graph gives you an idea of how hard the analyzer is working.

The voltage readout seen just above the waveform (shown as 2040 in this example) shows you the voltage level as you increase the voltage with the footswitch or voltage output control knob.



Creating a Surge test reference

Creating a reference waveform involves determining and setting parameters collected from a known-good reference motor.

1) To acquire a reference waveform, check the Edit Test ID box in the Tests tab, and turn on the Surge test.

2) Click on the Surge test configuration button.

Figure 69. Edit Test ID box checked in Tests tab.

3) When the Surge Test setup window opens, set the desired voltage, Zero Crossing, and both L-L EAR and P-P EAR tolerances.

4) The Volts/div and µSeconds/Div parameters default to auto; however, if you know these settings, enter the values to give yourself a better view of the waveform. If you do not know the settings needed, leave them at auto and run a test to determine the best setting to use. Then enter the settings before running further tests.

Figure 70. Surge Test reference parameters setup.



NOTE

It is important when comparing waveforms that all settings are the same. If the scales are different, a valid comparison cannot be made.

5) After the test parameters have been modified as needed, click the Close button to return to the Main window, Tests tab.

6) Click on the Save button to save the parameter changes, but do not uncheck the Edit

Test ID box. You are now ready to test a known-good motor to obtain your Surge test reference.

Testing a reference motor

1) To obtain the reference test, ensure that the Edit Test ID box in the Tests tab is checked. Immediately after setting up the test parameters, connect the reference motor to the analyzer and confirm that the Motor ID displayed on 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 Surge

Test window. Otherwise, you can click on the Surge Test run button in the Tests tab and proceed.

3) In automatic mode, the test will commence on its own. For other modes, click on the

All Lead button to start the test. The analyzer will raise the test voltage to the define level and conduct all defined measurements for each test lead. For a known-good motor, all tests should pass. When the tests complete, the tester will return you to the Tests tab (in automatic mode; other modes, click Close to return to the Tests tab.

Figure 71. Surge Test reference waveform acquisition in progress.



4) A message dialog appears to confirm that you want to save the test result as a reference.

Figure 72. Confirmation dialog to use waveform as a reference.

5) If the results are good, click Yes . If the test needs to be run again, click No . Multiple tests can be run to obtain the desired reference. In automatic mode, test results are always saved. The reference will become part of the Test ID only when Yes is clicked in the 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 the process, click Save then uncheck the Edit Test ID box to turn off edit mode.

NOTE

If the reference waveform is no longer needed or if has been created by accident, uncheck the Test-Ref EAR(%) and click the Done button, then update the Test ID and it will detach the reference waveform from the selected Test ID.



Testing a production motor by comparing with a reference motor

1) Select the Motor ID for the production motor to be tested. Ensure that it uses the same Test ID as the reference motor. If the subject motor has not been entered into the database, add it via the Data tab Nameplate view, ensuring that it is the same type of motor as the reference. Then ensure that the proper Test ID is assigned.

2) You can confirm that the selected Test ID has a waveform attached by viewing the

Surge Test setup window. The Test-Ref EAR (%) box will be checked and a Display

Ref button will be visible.

3) Click on the Display Ref button and the reference waveform will be displayed.

Figure 73. Display reference button.

4) Click Close to return 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 will automatically continue with the Surge test.

7) If the software detects a reference test, it will calculate the Error Area Ratio (EAR) at the end of the Surge test. The EAR is calculated between leads of the motor under test and compared to the reference motor test results. The software will then compare the EAR values with the tolerances entered in the Surge test parameters. If the EAR values are within tolerance, the motor passes. Conversely, if an EAR value is outside the tolerance, the motor fails. After the test has been performed and saved, surge waveforms can be examined via the Data tab Surge view.



Viewing Surge test results

To examine Surge test results go to the Data tab, Surge view. If the Test ID used has a reference motor attached to it, the software displays the selected motor’s surge waveform

(solid lines) and 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 waveform so only the solid lines are viewed. To see one lead at a time, check or uncheck the desired lead’s check box.



Using the Trending tab

Clicking on the Trending tab brings up a graph that charts acquired data. Trending information such as Max Delta R%, Balance Resistance, L-L Resistance, Coil Resistance,

MegOhm (correct or not corrected), PI, and HiPot leakage currents can be graphed over time so you can get an idea of the 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 the screen to zoom in on a specific area. You can also use your finger to draw the box around the area you want to zoom in on. Click on the Reset button to return to full view.

Figure 75. Trending graph.



Max Delta R%

Max Delta R% identifies the maximum resistance difference percentage between all three test leads. This imbalance as it is commonly known is collected during each test conducted on the motor. The results are plotted in this graph with the test date and time shown in the X axis.

Figure 76. Max Delta R% trending graph.

Resistance Trending Graphs

There are three different types of resistance data that can be trended: balance, 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 interval.

Each of the three leads is shown in its own color. Each data point is indicated by a square, diamond, or triangle marker. Hovering over a data point will show a date/time stamp and give the value of the test. This feature allows for easy identification of the test record for that point.

72

Figure 77. Resistance trending graph.



Insulation Resistance/MegOhm

MegOhm data is graphed by clicking on the Megohm Trend item in the dropdown list.

Hovering over a data point shows a date/time stamp and gives the value of the test.

Figure 78. MegOhm 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 not possible to acquire the temperature of a motor when testing due to inaccessibility of the motor.



PI

Clicking the PI button displays the graph trending the PI ratio versus time, and has similar features to the other trending 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. HiPot trending graph.



Relative humidity

Checking Relative Humidity (RH%) adds the RH percentage value entered at test time to the tool tips displayed when you hover over a data point. Default values displayed in the tool tips include the Time/Date stamp and measurement value of the point.

Special software trending features

On occasion, only a certain time period of data is desired, or some invalid points need to be excluded. You can select specific data points using one of two methods. The first is when the trending graph is displayed. 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 inside the box you drew.

To reset the graph, click on the Reset button then all points will be displayed.

Figure 81. Special trending features

The second method is to choose points from a list of all test dates/times.

Clicking the Select Dates button open a window showing all test dates and times along with a spreadsheet style view of the data. All of the data can be selected or just specific tests.



Most often, this feature will be used to exclude a test that contains known bad data that, for example, might be acquired in a test that was aborted.

To select or deselect dates, use the same type of selection techniques used to select files in

Windows Explorer.

1) Click the left mouse button to select a single record.

2) Click on the first record.

3) Click the Shift key on your keyboard and click on the last record to select a range.

4) Within a selected range, click the Ctrl key on your keyboard and click on individual records to remove 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 into a spreadsheet. In this manner, data can be analyzed using your preferred tools.

1) To create the CSV file, select the test date/time to export or select None and all data will be exported.

2) Click on the Create Text File button and enter a file name.

3) The application will create a comma-delimited file. This dialog will also allow printing of all the data see in the list box. Click on Print List to print all selected data.


6 Test procedures

Before testing begins

The starting point for conducting all motor testing involves creating a Motor ID and assigning or creating a Test ID that is properly configured for the motor under test.

Testing options include fully automatic testing, semi-automatic testing, and manual testing.

Examples of each type of testing are provided in several areas within this and other chapters.

Recommended testing sequence

To adequately test motors and to establish effective predictive maintenance programs, we suggest using a specific test sequence. The general idea is to perform the test sequence as a series of progressively more 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.

CAUTION

Test lead clips have exposed metal areas. Do not touch the clips while tests are running. Always exercise caution to ensure that test clips are not placed in proximity to the frame or any ground potential. Coil and properly store unused test leads in a safe location.

The suggested testing sequence is:

1) Resistance

2) MegOhm, polarization index (PI), dielectric absorption (DA)

3) HiPot, ramp voltage, step voltage

4) Surge

NOTE

This chapter includes brief descriptions of each test type conducted with the Baker

AWA-IV analyzer. For more details on the theory and application of each test, refer to the Motor Testing Theory Reference Manual.

Test procedures

Balance resistance test or line-to-line resistance

A coil resistance test looks for resistance imbalance between phases. If a large imbalance is found, the motor should be inspected for the cause of the discrepancies. Typical problems include:

• Hard shorts to the motor’s core.

• Hard shorts between coils; either within the same phase or between phases.

• Coils rewound with the improper gauge wire.

• Loose or corroded connections.

• Opens.

No further testing is necessary until the reason for an errant measurement is determined and corrected, and a satisfactory resistance measurement is obtained.

NOTE

Rotors installed during testing can also affect resistance testing because if the rotor turns at all during testing, the system cannot settle out the changes and determine a proper resistance value.

MegOhm test

A MegOhm test is performed using a test voltage based on the operating voltage of the motor and the appropriate standards/company guidelines. Look for an unusually low

MegOhm value when compared to previous measurements or industry-accepted limits for the type of insulation in the motor. If a low MegOhm value is measured, the motor should be inspected for ground wall insulation damage. Possible problems include:

• Slot liner insulation or enamel wire insulation may be burned or damaged.

• The motor might be full of dirt, carbon dust, water, or other 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 reason for a low MegOhm reading is determined and corrected.

DA/PI test

The Polarization Index (PI) test is performed in order to quantitatively measure the ability of an insulator to polarize. When an insulator polarizes, the electric dipoles distributed throughout the insulator align themselves with an applied electric field. As the molecules polarize, a polarization (or absorption() current is developed that adds to the insulation leakage current. The additional polarization current decreases over time, and drops to zero when the insulation is completely polarized.

The PI test is typically performed at 500, 1000, 2500, or 5000 volts, depending on the operating voltage of the motor being tested. PI test duration is 10 minutes. The PI value is calculated by dividing the insulation resistance at 1 minute by the resistance at 10 minutes.

In general, insulators that are in good condition will show a high polarization index, while damaged insulators will not. (See IEEE 43-2000 for recommended minimum acceptable values for the various thermal classes of motor insulation.)

Many insulating materials do not easily polarize. As recommended in IEEE 43-2000, if the

1-minute insulation resistance is greater than 5000 megohms, the PI measurement might not be meaningful.


Test procedures

The PI test is performed on motor of 100 Hp or greater. The PI minimum alarm should be set a 2.0 for class B, F, and H insulation, and 1.5 for class A insulation.

It is important to note that PI should not be used as the basis for any motor acceptance criteria. It should be used as a trending and diagnostic tool, along with other test results include the PI curve generated by the tester.

The PI test can be used to identify the following possible motor issues:

• Slot liner insulation or enamel wire insulation could be burned or damaged.

• The motor might be full of dirt, carbon dust, water, or other contaminants.

• Motor windings shorted to ground.

• Poor cable insulation.

The DA is essentially the same as PI, but shorter in duration (10 min vs 3 min). The first minute for both tests is the megohm test.

HiPot test

A HiPot test is performed using a test voltage that is substantially higher than the MegOhm test; however, it should be based on the motor’s operating voltage and the appropriate standards/company guidelines.

During HiPot testing, look for unusually high leakage currents, a leakage current that does not stay constant, or a leakage current that intermittently jumps up and down.

Breakdowns or high leakage currents are indications of damaged ground wall insulation.

Inspect the motor’s slot liner, wedges, conductors between the junction box and the coils, and so on.

No further testing is necessary until the reason 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 of what the motor typically experiences during starting and stopping. The test voltages are governed by IEEE or other industry-accepted standards organizations such as NEMA, EASA, and IEC.

The DC voltage is applied to all three phases of the winding, raised slowly to a predetermined step level, and held for a predetermined time period. This is continued until the target test voltage is reached.

Because the test is most stable at the end of each step, data is logged at that time. If at that time the leakage current (IµA) doubles, insulation weakness is indicated and the test should be stopped. If the leakage current (IµA) increases consistently less than double, the motor insulation is likely in good condition.

Surge test

A Surge test is performed on each phase of the motor, using a test voltage based on the motor’s operating voltage and the appropriate standards/company guidelines.

Look for a jump to the left of the surge waveform pattern; this is the signature of a turn-toturn short. If a jump is observed, inspect the motor. Look for damaged insulation between adjacent conductors.

The insulation might be hard to see, so you might have to disassemble the motor to find the problem. If you do not observe a jump in the wave patterns, the likelihood of motor failure due to turn insulation failure is greatly reduced.


Test procedures

Recommended test voltages for insulation resistance testing

The following table provides guidelines for DC voltage applied during insulation resistance test. Test voltage should be applied for one minute. (See IEEE 43, sections 5.4 and 12.2.)

Winding Rated Voltage (V) a

<1000

100–2500

2501–5000

Insulation Resistance Test Direct Voltage (V)

500

500–1000

1000–2500

5001–12,000 2500–5000

>12,000 5000–10,000 a Rated line-to-line voltage for 3-phase AC machines, line-to-ground for single-phase machines, and rated direct voltage for DC machines or field windings.

Recommended test voltages for HiPot and Surge tests

The general recommended voltages for HiPot and 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 (for test voltage greater than

5000 volts), and IEEE 43-2000 (test voltages less than 5000 volts).

For example, the test voltage for a 480-volt AC motor would be:

2 x 480V + 1000V= 920 + 1000 = 1960 V

Likewise, the test voltage for a 4160-volt AC motor would be:

2 x 4160V +1000V = 8320 + 1000 = 9320 V

For new windings or rewound motors, the test voltage is sometimes increased by a factor of

1.2 or even 1.7. This provides for a higher level of quality control on the work performed.

For example, for the 480-volt motor, the test voltage would be:

1960V * 1.2 = 2352V

Or

1960 * 1.7 = 3332V


Test procedures

Performing an example test

The following section walks you through an example setup of a motor being tested for the first time.

• First, you will create a Motor ID that uniquely identifies the motor being tested.

• Next, a Test ID must be created for the motor and assigned to the Motor ID.

• Then tests will be run and the results reviewed.

• Finally, reports will be printed.

Creating a Motor ID

1) Often times, when a new motor is being added to the database, a similar motor already exists. In such cases, you can select the similar motor using the Explore tab.

2) From the Data tab— Nameplate view, the Motor ID information is displayed for the selected motor. As the view name suggests, the information presented here comes directly from the motor’s nameplate. The information presented was entered by a user when the original Motor ID was created.

3) When starting with information from a similar motor, you can click on the Add button to clear the Motor ID and SN (serial number) fields. Then, you can simply enter the a new unique Motor ID and serial number for the new motor, provided that the existing information matches the values on the new motor’s nameplate. If other nameplate information for the motor is available, you can 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 click on the Clear button to clear the nameplate form. Then, you will provide a new Motor ID along with all information found on the nameplate.

5) Use the Tab and Shift/Tab keys to easily move from field to field.

NOTE

In most cases, only the Motor ID, Location, and Building fields are required.

However, adding all available information from the nameplate has proven valuable for many applications including report generation, internal and external troubleshooting, and support.

If the Enable Voltage Class feature has been enabled, the Volts Oper (operating voltage) field will also be required. If a voltage class for your motor is not available in the Volts Oper list provided, you can create a new motor voltage class as described at the end of this chapter.

Oftentimes, more data fields available than the information provided on the nameplate. Fill in only those fields that have corresponding information on the nameplate.

6) The Reset button restores the previous motor’s information to the form.

7) Ensure that the proper radio button is selected for Winding Config . This value will be used by the software during test setup.


Test procedures

8) Examine the example below to see how the Nameplate view appears when a new

Motor ID is created.

Figure 83. Example Data tab Nameplate view of new Motor ID.

9) After all data is entered, click on the Save button 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, we selected the 480V w/Rotor HiPot.

12) Click on the OK button. The new Motor ID is now added to the Motor Tree .


Test procedures

Creating a Test ID

In many cases, an existing Test ID selected when creating the Motor ID will work just fine for your needs. However, the purpose of this exercise is to acquaint you with the process should you need to create a new Test ID.

Figure 85. Creating a Test ID.

1) Click on the Tests tab. Notice that the Test ID that was assigned via the Test ID dropdown box when the Motor ID was created appears in the TestID field. However, for this example, 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, you will need to set up the password. To do this, click on the Change Password button and enter a password.

Then click on Set Password .

Click OK . When the application accepts the password. The Update, Add, and

Delete buttons will appear and the voltage class dropdown list will be enabled.

The Edit Test ID checkbox background will be red when in edit mode


Test procedures

4) Click on the Add button. The Create New Test ID dialog box appears.

5) Click on the Add Blank Test ID radio button.

6) Enter a descriptive Test ID. The standard convention used by the software is to start with the voltage class and add elements that indicate test elements intended for the

Test ID. For this example, we use 480V w/rotor DA Step to create a Test ID that will serve a 480-volt motor with rotor installed 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 not exist, you can create a new one by typing 480 in the edit box of the dropdown list.

8) If a new voltage class type has been entered, enter a description and click on the Add

Voltage Class button. A dialog box will appear asking if this action is correct. If it is, click OK . This will close the Create New Test ID dialog box.


Test procedures

9) The new Test ID will be displayed and all tests will be turned off.

10) Turn on all required tests by clicking the ON/OFF buttons in the left-most column.

The buttons turn green when they are on.

Figure 87. New Test tab view with new Test ID created and selected. All tests turned on.

Configuring Temperature/ Resistance test

1) The temperature and resistance tests share the same setup window. Click on either the Temperature or 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 selected, the Temperature Enable radio button is green.

3) Click on the Manual Temperature Entry radio button.

NOTE

The Baker AWA-IV will accept both ° C (Celsius) or ° F (Fahrenheit) temperatures and a temperature range of -32° C to 250° C. If you choose not to use

Temperature entry, click on the radio button and it will be disabled (grayed out).


Test procedures

4) Because the resistance test was chosen, the Resistance Enable radio button is also green. The motor in this example is wye-wound, which is indicated on the window and can be changed via the motor’s Nameplate tab.

Figure 88. Temperature/Resistance test parameters.

5) The 3 Leads and Automatic radio buttons will be selected by the software for the

3-phase motor. The analyzer will automatically acquire the resistance readings.

6) Depending on the model, some analyzers are equipped with a separate set of resistance test leads to perform a lead-to-lead low-voltage resistance test.

Resistance values must be greater than 0.500 ohms for high-voltage leads. If the high-voltage leads are used on a motor with resistances less than 0.500 ohms, the analyzer will prompt the operator to switch to low-voltage leads. For this example, the AWA model being used does not have the 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 temperature is enabled, the Correct to box is checked and defaults to 25° C and the value for copper is set to the IEEE 118 constant.

9) Target Corrected Resistance is a feature that refines the pass/fail criteria. If checked, the analyzer will fail a motor if the readings are not within tolerances. For example, the resistance reading for a motor can be taken using a DVM. Let’s say that the reading is 3.1 ohms. In this case, we can check the Target Corrected Resistance box and enter the value of 3.1 +/- 10%. One issue with using this feature is that enabling target corrected resistance makes this Test ID specific to a single motor. If resistance data is not available, or you want to be able to use the Test ID for other motors, do not enable this feature.

10) Click on the Close button.


Test procedures

Configuring DC tests

1) DC tests include MegOhm, DA/PI, HiPot, Ramp Voltage, and Step Voltage tests.

2) To configure one or more of these tests, click on any of the test configuration buttons to the right of the DC test buttons to open the DC Tests setup window.

3) For this motor, the MegOhm and DA tests will be run at 500 volts while the Step

Voltage test will be run at 2000 volts. Consult IEEE 43/95 or another appropriate standard to determine test voltages.

4) Because this is a small motor, the PI test will run only 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. DC Test parameters—MegOhm and DA parameters set.

If you click on the DA Only dropdown list, you will see another option called Revert DA.

Selecting this test option sets up the analyzer to automatically skip the PI test in favor of the

DA test at three minutes if the insulation resistance (IR) is greater than 5000 MegOhms at the one-minute mark. Insulation resistance readings of 5000 MegOhms or greater at one minute is the generally accepted criteria for aborting the PI test.


Test procedures

5) Click on the HiPot/Step Voltage dropdown list to select the Step Voltage test (for this example). The Ramp Voltage test option is also selected from this list.

Figure 90. DC Test parameters—Step Voltage parameters set.

6) When you select the Step Voltage option, the Config Wizard opens so you can define the parameters needed for your test. The software will automatically calculate values for the test based on other parameters entered, but you can adjust the parameters as needed to fit your situation. When you have settled on the parameters needed, close the Config Wizard to return to the DC Test setup window.

7) In the example above, we see that parameters are set for the Step Voltage test.

8) Click on the Temp Correction dropdown list to select the insulation type for you motor. Options include Thermoplastic or Thermosetting . Choose None if you do not want to set this parameter.

9) If you choose Thermoplastic or Thermosetting , the correction field will be enabled so you can set the value needed for temperature correction.

10) When you are satisfied that your DC Tests have been configured as needed, click the

Close button to return to the main test window.


Test procedures

Configure Surge test

1) Click on the test configuration button to the right of the Surge button to open the

Surge Test setup window.

2) Configure the Surge test as shown. Set the Surge Voltage to 2000 volts, which is approximately 2 X V + 1000.

3) Set VRamp Rate to a typical 25 volts. If the test should run faster, increase this number to 50 or 100 volts.

4) For this example, we set the Surge Pulses number to 5, which means that five pulses will be applied to the windings after the analyzer reaches its maximum test voltage of 2000 volts.

5) Set the Volts/Div and the µSeconds/Div to Auto. The analyzer will automatically scale the waveform to fit the graph.

Figure 91. Surge test parameters.

6) L-L EAR (%) (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 phase winding unless the pass/fail value is set to a high number such as 50 percent.

7) The P-P EAR (%) (Pulse-to-Pulse EAR) is set to 10 percent. This means that a pulse-to-pulse EAR value greater than 10 percent will cause the analyzer to stop testing and the motor will fail the test. This number can be reduced provided the voltage ramp rate is also reduced.

8) The Zero Crossing option is not used in this example. When used, the percentage set for the option is the threshold at which the test will fail if the waveform shifts to the left and crosses the zero reference line outside the defined threshold.


Test procedures

9) The Test-Ref EAR(%) is also not used in this example because this motor does not have a reference motor/waveform associated with the test. If the feature was available, we could set the value to say 10 percent; then the acquired waveforms would be compared to the reference waveform. If the EAR values between reference waveforms and acquired waveforms were greater than the value shown, the motor would fail the test.

10) Checking the Pause Between Leads box tells the tester that you need additional time between testing lead 1 and 2, and lead 2 and 3 typically to reconfigure the leads before continuing with testing. In most cases, the feature is not needed; however, if you have an atypical application such as performing a three-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 documented elsewhere and are not used in this example.

12) When you are satisfied that the parameters have been properly set, click on the

Close button to return to the Tests tab. Labels on the test configuration buttons will change to indicate values defined during the setup process.

Figure 92. Surge test parameters.

13) From the Tests tab, click on the Save button to update the database with the new test information. From this point, the test parameters defined will be used to test the subject motor or any other motor that has this Test ID assigned to it.

14) Uncheck the Edit Test ID box after you click Save to end the editing process.


Test procedures

Running an automatic test

After new Motor and Test IDs have been created, a fully automatic test can be run. It will test the motor in the following sequence:

1) Temperature

2) Resistance

3) MegOhm

4) PI/DA

5) HiPot/Step Voltage/Ramp Voltage

6) Surge

At the end of the sequence, the test data will automatically be saved to the database.

NOTE

Tests can also be run from the test setup windows using a semi-automatic or manual process. Semi-automatic tests can be executed by pressing the desired run button on the Tests tab.

Additionally, tests can be run manually using the controls on the front panel of the analyzer.

1) To start an automatic test, select the desired Motor ID using the Explore tab.

2) Click on the Tests 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 this example.

3) To start the test, click on the red Run Auto Test button in the Tests tab and follow the directions.

4) The Safe to Turn On dialog box appears, instructing you to verify that the correct set of leads is properly connected. If the resistance test is turned on and the Res Leads box is not checked, this dialog box will direct you to attach the high-voltage leads. If the Res Leads box is checked, the displayed dialog will request that low-voltage leads be attached.

NOTE

The test leads available and the corresponding directions presented by the software depend on the tester model that you will be using.


Test procedures

Figure 93. Safe to turn on notifications—model dependent.

The following sequence of tests will run automatically:

• Temperature —The Temperature/Resistance Test setup window will open, ready for the temperature reading to be entered manually. Readings are taken using an external device. Enter the temperature reading then click the Accept button to acknowledge the entry and inform the software to proceed with the next test. The analyzer will automatically proceed with the remainder of the tests.

• Resistance —If the readings pass per the requirements of the Test ID, the

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 to operating voltage (500 volts for this example). This voltage will be held for 60 seconds during which the analyzer watches for overcurrent trips or insulation resistance values below the minimum

MegOhm setting. If a failure is detected, all testing will stop, and the test leads will be discharged and grounded. You will be given the choice to repeat the test, stop all testing, or continue to the next test.

92

Figure 94. DC Test setup window—appears when DC Tests are executed.


Test procedures

• PI/DA —The DC Tests setup window will switch its focus to the PI/DA tests column.

Because the Test ID in this example was set up for a Dielectric Absorption (DA) test, the duration of the test is three minutes (180 seconds). At end of the test, if no failures occur, the software will continue with the next series.

• HiPot/Step-Voltage/Ramp-Voltage —The test will begin automatically. For Step-

Voltage testing, a new window automatically appears to display the test results in progress. Preset 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 will immediately stop, and the leads will be discharged and grounded. You will be given the choice to repeat the test, stop all testing, or continue to the next test.

Figure 95. Step -Voltage test window—called automatically from DC Tests process.

If no failures are found during this test, the analyzer will close the Step-Voltage Test and DC

Tests setup windows, and continue to the Surge test.


Test procedures

• Surge —The Surge test will begin automatically. The Surge Test setup window appears and the test voltage slowly ramps up on lead 1 to 2000 volts as specified by the Test ID. If no pulse-to-pulse EAR failures are been detected, leads 2 and 3 will be tested in turn. If a test fails at 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 from all tests will be saved to the database and the main test window will re-appear, showing the general results in the Tests tab.

94

Figure 97. Main window—Tests tab—with passing test results.


Test procedures

Reviewing test results/data

After the test results have been saved to the database, they can be reviewed using the Data tab in the right pane of the software’s Main window. The Results Summary tab has a Date/

Time area on the top part of the window and a spreadsheet style view of the data on 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 the tests passed or failed. Double click on a test date and time to move to a new record.

You can also right click on a record to open a Delete dialog box if you choose to remove a specific test record.


Test procedures

If you want to expand a column to view more information, hover the mouse cursor over a column’s edge until the cursor changes to a two-headed arrow, then click and hold the left button down while dragging the edge to create 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 the top of the window with specific measurement results shown in each column.

Figure 101. Test results spreadsheet; lower section.


Test procedures

The PI test can be reviewed by pressing the PI tab. PI view will display the PI/DA graph along with a table of the current and MegOhm readings gathered at specific times. The PI voltage,

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 test data.

Click on the Surge tab to view surge test data.

Figure 103. Surge waveform view.


Test procedures

Printing reports

The Baker AWA-IV’s software includes report generation features so you can provide test results to managers, customers, and repair personnel as required. Reports containing test data, nameplate data, application data, and more can be sent to a printer, or they can be printed to a Microsoft Word file or other file formats as needed or preferred. For convenience, you can print reports from a desktop computer rather than from the analyzer itself.

Figure 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 section of the Main window.

The top section of the Report Generator —called Select Filter(s) —contains filters you can use to select which tests results you want to print. Select the current motor and test result, or use any combination of the other filters as needed. For example, you can select a date range and all motors that failed any test during the selected test range.


Test procedures

When you need to print data for several motors, you can select and print them one at a time, or you can select all records that match specified criteria using the report filters. Different combinations of the motor’s location fields, date range, and/or pass/fail criteria help you select specific groups of reports.

Figure 105. Select Filters section of the Report Generator window.

After you select your test results, you will use the bottom section of the Report Generator window—called Select Reports —to select the report type that you want to print. You have several choices including Nameplate, Application, Summary, Surge, PI, and Step Ramp

Voltage to name a few. You can also add a report title, which will appear in the final report.

After selecting the report type you need, click on 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 Bar EAR CSV

File.

Figure 106. Print selected reports.

In the simplest case, you will want to print the test result being reviewed. The motor and test result selected in the main program will appear to the right of the Current motor/test checkbox in the Select Filter(s) section. Ensure that box is checked then check the box(es) in the Select Reports section for the type of report you need. Select Printer from the Output

Report To dropdown list then click on the Create Report button.

In other cases, you will want to print a more specific set of reports and/or data for a collection of motors tested. Just be sure to carefully consider what you need so you can generate the results required.


Test procedures

Using an example where an electrician tests many different motors during the day and needs to print reports for failed motors before going home. In this case, the Report Generator window should be configured as shown below.

1) The Select Filter(s) section has the Date Range selected and both dates are set to

3/17/2017 so the software will only include test results for that day.

2) The Pass/Fail filter is selected along with the FAIL radio button so that results for motors that have failed one or more tests will be included. Passed tests will not be included because that radio button is not selected.

3) In the Select Reports section, the Results Summary with Surge Summary is selected. The Printer 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 software completes its search, a dialog box appears showing how many records were selected. Clicking on Cancel stops the process; clicking on Continue completes the report generation and printing process.

Figure 107. Report generation example

NOTE

The Report Generator can be set up so that a large number of reports are created.

Printing out a large number of reports can be very time consuming, especially when going to Microsoft Word. The Report Generator will show how many test results are chosen; however, this is not the number of pages that will be printed.

That depends on the number of reports chosen.


Test procedures

The program can also print reports to Microsoft Word—if it is installed on the analyzer—or on a desktop computer running the software. This feature provides a way to annotate reports by adding text to the Word document as required. For example, a comment regarding the vibration level of the motor before it was turned off can be added to the Word document. This feature should also be used with 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 Word report is shown below. Each section is a Word table; except the surge waveform, which is a bitmap. The reports can be modified by adding text between the tables or the data tables can be cut and pasted into other documents.

Figure 108. Example MS Word report with nameplate, summary, and surge graphic.


Test procedures

In the following example, we see a report that includes the Results Summary and the Surge

Summary.

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 file.


Test procedures

Creating a new motor voltage class

If an appropriate motor class is not available for your specific motor, you can create a new one following this procedure.

1) Open the Tests tab.

2) Check the Edit Test ID box and enter password as needed.

3) Click the Add button.

4) Click the Add Blank Test ID radio button to enable the fields below.

5) In the Target Motor Voltage Class field, enter 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 create a new Test ID as well.

Figure 110. Creating a new motor voltage class via the Create New Test ID dialog.

7) Click on the Add Voltage Class button then click Yes in the confirmation dialog that appears next.

8) The new motor voltage class will be added to the list for future use.


Test procedures

Surge testing notes and recommendations

The following notes are provided for additional insight into specific Surge testing issues and situations.

Surge testing with rotor removed (typically motor shop testing)

• Enable L-L EAR and set tolerance to 2% (form wound motor).

• Enable LL-EAR and set tolerance to 3% (random wound motor).

• Enable P-P EAR and set tolerance to 10%.

• Disable zero crossing.

Surge testing with rotor installed (typically field testing)

• Enable P-P EAR and set tolerance to 10%.

• Disable L-L EAR when testing in the field.


Surge testing DC motors

• Disable P-P EAR.

• Enable L-L EAR when testing in the field.


False P-P EAR failures

In some motors, the waveform 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 generate a false failure. To eliminate this nuisance trip, increase the surge test voltage in 25 volt increments.

Surge test underpowered

The Surge test is load dependent. Anything that adds capacitance to the motor under test will increase load on the tester. If the motor draws more energy than the tester can deliver, the test will fall short of the recommended test voltage. The will be realized when the energy bar on the right side of the Surge test window tops out and the surge voltage stop below the expected test voltage. If this occurs, a larger surge tester with more joules of energy should be used.


Test procedures

Surge testing through capacitors

When Surge testing a motor, all capacitors should be removed or the ground should be lifted.

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 prevent surge pulse absorption.


Test procedures


7 Special features of the Baker AWA-IV

Predictive maintenance

A program of predictive maintenance testing requires that motors periodically be taken offline

(powered down and removed from service) and tested with the same parameters each time.

This provides a reliable picture of the motor’s condition. Predictive maintenance allows spare parts to be stocked, rewinds or other refurbishments to be scheduled, and minimizes the likelihood of unscheduled down time.

Figure 112. Resistance trending screen.

Trending data collected and stored by the Baker AWA-IV is particularly useful for predictive maintenance. Test parameters must be identical for data trending to be meaningful. Tests at different voltages will render data less useful for trending. If Test IDs are programmed 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 maintenance testing, failure of a test indicates possible motor problems. Additional testing—for example, visual inspection—might be warranted. The combination of tests should be determined by experienced operators. If the source of the problem is electrical, the

Baker AWA-IV’s manual mode can be employed to conduct further testing.

As an example, consider the case of wet windings. The motor is likely to pass resistance tests, fail MegOhm tests, fail HiPot tests, and pass surge tests. After the failed MegOhm test, no further automatic testing will be done unless you use the continue option. Knowledge of motor behavior will help an experienced operator conduct visual tests or further electrical tests with the analyzer in manual mode to isolate the source of the problem.

Special features of the Baker AWA-IV

Quality control

Quality control testing done in a rewind shop or production facility could use relatively higher voltages compared to maintenance testing of the same motor. In a quality control testing environment, the test results are either pass or fail. Data is not trended and diagnosis is not a goal. Rather, the insulation system of a newly-rewound motor must be able to withstand test levels in accordance with IEEE and NEMA standards.

When conducting quality control tests, failures must be analyzed. For example, some winding configurations will fail a winding resistance test with seemingly reasonable test parameters even when the winding resistance is good. Knowledge of special windings is important and can only be provided by those responsible for the winding.

Motor troubleshooting

In the case of a motor failing during service, the analyzer can help determine the root-cause 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 surge test on the windings. The shorted winding will generate a waveform substantially different from the two good windings.

Motor shops can use the Baker AWA-IV to indicate where a problem has occurred, pinpointing what needs to be repaired. Additionally, test results provide a tool for recommendations to the customer.

Field coils

When testing field coils, follow the procedures outlined for testing single-phase motors, twoterminal devices, and synchronous motors/generators. The recommended surge test voltage for DC fields is 600 volts.

If the impedance of the coils is very low (fewer turns, generally form coils with very low resistance), the surge tester standalone might not adequately test the coils. A bar-to-bar, low-impedance test accessory from SKF might be needed.



Hi L in Baker AWA-IV 2 kV and Baker AWA-IV 4 kV

Hi L is a technique that extends the range of the base surge test circuitry in Baker AWA-IV 2 kV and 4 kV models. This circuitry, like all electrical circuits, has design and operational characteristics that can be enhanced or fine tuned to meet specific additional requirements.

Hi L technique is an example of this.

In essence, the useful range of electric coils that the analyzer can test is dictated by the capacitance (C) supplied by the test set, and the inductance (L) of the coil under test. The “Q” factor—or loss of the test object—also has a direct influence.

Per the data specifications, the Baker AWA-IV 2 kV and Baker AWA-IV 4 kV models are supplied with a .1 microfarad energy storage capacitor. To illustrate the phenomena at work, this value (0.1) shall be the basis of the following discussion.

The sample, or data acquisition window, of the Baker AWA-IV 2 kV and Baker AWA-IV 4 kV is dictated by its analog-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 applied, measured, analyzed, and displayed in a fraction of a second.

The Baker AWA-IV 2kV analyzer has a 0.1 micro-farad capacitor. The frequency (f) generated—and therefore, the sample width needed—when a 100 micro-henry coil is tested with the standard surge test is calculated using the following formula:

becomes

when solved, reveals a ringing or resonance frequency of approximately 50 kHz. The period of said 50 kHz sinusoid is equivalent to or approximately 0.00002 second. This is well within the sample window width detailed previously.

What happens to these frequencies if the inductance of the tested coil is raised by several orders of magnitude? For example, what if the coil inductance is now 5 henry, or 50,000 times greater?

when solved, reveals a frequency of approximately 225 hZ

The period of this signal is or approximately .0044 seconds.



This is more than double the capability of the data acquisition sample width hardware used to capture it! Therefore, the question becomes: how do we capture such a signal and display it appropriately across several orders of magnitude?

The answer is to employ the Hi L technique. The Hi L technique, in practical terms, functions as a test range extender. It allows the Baker AWA-IV 2 and 4kV models to deliver sensitive test results when employed on much higher inductances than the standard Baker AWA-IV surge test circuit.

Using the Hi L technique

The Hi L technique can be used to test DC shunt or compound motor insulation, evaluate shunt fields, and test interpoles.

Fully testing DC shunt or compound motors with the Baker AWA-IV requires some additional programming and consideration of the motor in terms of its separate windings.

Knowing that the separate windings can operate at different voltages helps determine appropriate test voltages. Because there are separate windings, Test IDs need to be tailored to the windings.

An effective method of performing this test sequence 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 surface contamination due to brush carbon or other materials. A suitable Test ID should include:

• Temperature correction.

• Kelvin resistance (with two leads selected).

• MegOhm, with a suitable value of pass/fail for the MegOhm value defined.

• DA/PI test, with a suitable value of pass/fail defined.

• DC Test, such as the DC Hipot.

• Standard Surge test (with two leads selected, by virtue of two leads resistance).

Test ID #2—Shunt Fields

Shunt fields are generally high inductance, quite higher in resistance, and arranged in pairs.

Using the Hi L technique could result in more sensitive evaluation characteristics.

• Temperature correction.

• Kelvin resistance (with two leads selected).

• MegOhm, with a suitable value of pass/fail for the MegOhm defined.

• DA/PI test, with a suitable value of pass/fail defined.

• DC test, such as the DC Hipot.

• Surge test (with two leads selected, by virtue of two leads resistance), and Hi L selected.

NOTE

The Hi L technique is only selected for the shunt fields!



Fine tuning the technique

The examples use a 10-hp DC Motor, stabilized shunt, 500-volt armature, 240-volt field.

Motor leads are marked F1, F2 (shunt field leads) 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. Tests tab for 240V DC shunt fields Test ID.



The Tests tab for the armature could look like the following example.

Figure 114. Tests tab for 500V armature Test ID.

Because we know this is a DC stabilized shunt motor, further test enhancement is possible:

• Expect the DC resistance of the armature (A1–A2) to be quite low.

• Expect potential brush 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 resistance detection for trending.

• Consider employment of Test-Ref, for A1–A2 and F1–F2 for trending.

• Consider steps to code, or lock the acquisition time-base for the specific motor.



Fine tuning tests for each Test ID involves ensuring that specific features are selected and their parameters adjusted for the specific motor.

Ensure that the Edit Test ID box is checked as you modify parameters for each Test ID.

1) For both Test IDs, open the Temperature/Resistance Test setup window. Click on the

Temperature Enable radio button, and consider enabling Target Corrected

Resistance (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 that the 2 Leads and Automatic radio buttons are selected.

Figure 115. Hi-L temperature resistance.

4) The DC Tests setup for each Test ID need only be adjusted for specific settings of the motor being tested. They do not require any special consideration for using the Hi-L technique.



5) The Surge test parameters will need to be adjusted for both Test IDs. Given that you are now aware of the low resistance of the armature, take steps to code the surge test sequence specifically for the low resistance. This equates to a lower value of time-base, (not necessarily 10, it could be 50).

6) For the shunt 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, and be sure to select Hi L.

8) Click Close then click Save to commit the changes for the Test ID. Uncheck the Edit

Test ID box.

Figure 116. Surge test settings for shunt fields Test ID; Hi-L selected.



9) For the Armature Test ID, you need only set micro-seconds to 200, and ensure that the Hi L option 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.



When you have completed your test setup and executed the related tests for both Test IDs, your compiled test results will look similar to the example shown below, with results shown for field and armature within the same Motor ID.

Figure 118. Hi-L armature and field test results list in Data tab.

Again, using this approach, you need 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 each Motor ID. In this instance, you will not need to remember to select and run two Test IDs for the single Motor ID; however, you will need to run each Motor

ID separately and combine test results manually if needed.


8 Using power packs with 6/12 kV models

The Baker AWA-IV 6 kV and 12 kV analyzers can be used with the Baker PP30 and PP24 power packs, which allows you to test larger, higher voltage motors that are beyond the capabilities of the testers alone. Generally speaking, the Baker AWA-IV 12 kV analyzer can test motors up to 1000 HP, 4160 volts, 1800 RPM on its own. Power packs are used to extend the testing capability of the standalone testers.

Power packs cannot be used alone to test motors; the control functions of the Baker AWA-IV are required.

You should review and clearly understand the instructions for stand-alone operation of the

Baker AWA-IV before attempting to operate the device with a power pack.

CAUTION

During testing, do not allow the Baker AWA-IV test leads to lie anywhere near the power pack test leads!

Be sure the Baker AWA-IV test leads are some distance away from the power pack test leads; preferably on top of the Baker AWA-IV or 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 separated

High voltage is activated when using this product. Ensure that all personnel are away from the device under test and not in contact with the load or test leads.

Never attempt testing a load with both the analyzer and power pack leads attached to the load at the same time.

WARNING

Some test leads will be open during the test and can be at the same voltage potential as the winding! To avoid severe injury or death, all precautions should be taken to avoid touching these leads!

NOTE

The ground fault system on the Baker AWA-IV will render it inoperative without a proper ground. When the host analyzer is connected to a power pack, an inoperable condition will also affect the power pack due to loss of the surge enable signal.

User safety demands that the analyzer output never be activated without connection to a winding load of some type. Refer to the host analyzer instruction in this manual for connection procedures to various windings.

Using power packs with 6/12 kV models

Power pack setup

NOTE

The power pack must show on its rear panel that it has been calibrated for the specific serial number of the Baker AWA-IV being used to control the power pack.

The power pack’s calibration is certified only with the Baker AWA-IV that shipped with it.

1) Connect the power pack to the analyzer. Use the short AC line cord on the power pack front panel or on the left side of the unit to connect to the AWA’s power entry receptacle.

2) Connect the 25-pin interconnect cable to the two units. The cable is marked on each end. Be sure to plug in the end marked HOST into the 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.

3) Connect the long AC power cord to the power pack front panel receptacle and then to an appropriate 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 and the power pack. Follow the Baker AWA-IV setup procedures in this manual.

5) After a one or two minute warm-up period, both units will be ready for operation.

NOTICE

If the power pack connection to the Baker AWA-IV is maintained and the power pack is turned off, I/O lines are influenced. This may cause problems with Baker AWA-IV operation.

CAUTION

When using the power pack for high-voltage testing, make sure:

1) The Baker AWA-IV’s leads are out of the way.

2) The Baker AWA-IV leads are not hooked together.

3) No printer or other devices are connected to the USB ports.

Operating position

The power pack is not rated for operation in any position other than vertically, with all four wheels down and on a level service.



Combining Baker AWA-IV host and power pack tests

To completely test a large motor, functions from both the Baker AWA-IV host and the power pack are used together. The Baker AWA-IV host is used to perform the winding Resistance,

MegOhm, and PI tests. The power pack is used to perform the HiPot and Surge tests. The test data collected by both instruments are then combined into a single test record in the database.

For this example, a 6600-volt 1785-RPM motor will be tested at 6000 volts for the

MegOhm/PI test and 14200 volts for the HiPot and surge tests. Both a new Motor ID and a new Test ID will be created.

Because this is a large slow motor, the Baker AWA-IV 12kV will not be able to reach the surge or HiPot test voltage (14200 volts) 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 Baker AWA-IV doing the resistance, MegOhm/PI tests, and the power pack doing the HiPot and Surge tests.

Creating IDs and setting up the test

1) Select the Data tab and Nameplate view on the right side of the Main window.

2) Click on the Add button to add a new Motor ID. The screen capture below shows a new motor called Main Heater Blower Motor. Using best practices, all other information available on the motor’s nameplate is entered into the Nameplate tab.

Figure 119. Creating a new Motor ID.

3) Click on the Tests tab to create a new Test ID.

4) Click on the Edit Test ID checkbox.

5) Enter the password for editing Test IDs.



6) Click on the Add button to open the Create New Test ID dialog box as shown below.

Figure 120. Creating a new Test ID.

7) Click on the Add Blank Test ID radio button.

8) Enter the new Test ID in the appropriate field. In this example, we use PP30_6600.

9) Use the Target Motor Voltage Class dropdown menu to select a voltage class. For this example, we would select a voltage class of 6600.

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 DC Tests setup window is shown in the example below.

Figure 121. Configuring DC tests a new Test ID.

Notice that all tests have been turned on, the desired test voltages entered, and the Enable

PP box under the HiPot column has 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 all testing for the requested time period to allow for sufficient time for the motor to discharge. The feature is more commonly used to discharge motors following DC HiPot testing.

CAUTION

If the windings are not allowed to completely discharge, a voltage can develop on the motor leads that can 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 checked to turn on the power pack for this test.

Figure 122. Surge test setup—PP30.

13) Click on the Close button to return to the Main window, Tests tab.

14) Click on the Save button to save the new test information for this Test ID. The

Password may have to be entered again to make the Save button visible.



Running the combined Baker AWA-IV and power pack tests

1) After you have properly configured the Test ID, click on the Run Auto Test button in the Tests tab.

2) The Baker AWA-IV will instruct you to connect the Baker AWA-IV analyzer’s test leads to the motor.

3) Press the M W and Lead 3 buttons on the AWA front panel simultaneously to start the test. The resistance test will start and run to completion followed by the

MegOhm and PI test.

After the PI test is finished, testing will stop, and the dialog box shown below will appear, instructing you to disconnect the Baker AWA-IV test leads and connect the power pack test leads to the motor. The power pack will be used for the HiPot and Surge tests.

Figure 123. Host analyzer lead disconnection and power pack lead connection 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 discontinue the test, or click on the Continue button to proceed with the test.

6) The Power Pack Push to Test dialog appears next as shown below.

Figure 124. Start power pack test message dialog.

7) This dialog instructs you to press the power pack’s Test button to begin testing. You will have to press and hold down the button to complete all tests. When you press this button, the Baker AWA-IV verifies the following:

• The analyzer’s test leads are checked to verify that they are open.

• The power pack’s Voltage Output Control knob is checked to verify it is in the minimum position.

• The Function knob is checked to verify it is in the proper position for the HiPot test.



Only after the steps above have been taken is the power pack output enabled.

You must keep the power pack’s Test button pressed during the above checks. After the power pack’s outputs are enabled, red lights on the power pack will illuminate showing that the power pack is active.

Increase the output voltage level until the target voltage is reached. Both the voltage and current display will be active while you ramp up the test voltage. If the voltage is ramped too quickly—by 1000 volts or more—the Baker AWA-IV will shut down the power pack and end the test.

After the test voltage is successfully reached, the test timer on the Baker AWA-IV’s screen will start counting down. When the test timer counts down to zero, the analyzer will automatically stop the test, disable the power pack’s test leads, and discharge the windings.

A message dialog will appear letting you know that the leads are being discharged. Continue to hold down the power pack’s Test button until you are instructed 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 not completely discharged.

To completely discharge, a large motor requires that the motor’s leads be held at ground potential for some time. IEEE 43/95 recommends a grounding interval four times the amount of time the high-voltage DC was applied to the windings.

If the windings are not allowed to completely discharge, a voltage can develop on the motor leads that can be high enough to present a shock hazard to personnel.

After the HiPot test successfully concludes, the analyzer will automatically start the surge test.

Because the surge test for this example is being run by the power pack, the analyzer will once again present screens instructing you to connect the power pack, press the Test button, and so on.

As with the power pack HiPot test, the Baker AWA-IV will automatically verify that the machine is set up properly before enabling the power pack output leads.



Testing with the Baker PP30 three-phase test lead power pack

The Baker PP30 power pack is supplied with three-phase test leads. The leads include three red cables and one black ground cable. All have insulating jackets and are rated at 60kV DC.

A black braided cable is also provided to connect the power pack to the motor frame or station ground.

The Test Select switch—located on the lower front panel—is used to switch between the different leads during the testing process, energizing the proper lead at the proper 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 connection to the motor.

NOTICE

The power pack

Function

and

Test Select

switches must be in the HiPot positions to perform a HiPot test. If the analyzer is not operated in this fashion, the tests will not be performed correctly, and the data recorded will be in error.

Do not switch the

Test Select

switch while a test is in progress. The useful life of the switching element may be substantially reduced.



Conducting DC tests with the Baker PP30 three-phase test lead power pack

1) After setting up the analyzer and power pack, on the Baker AWA-IV, select the motor to be tested from the Explore tab (motor tree view).

2) Click on the Tests tab to get to the main testing window.

3) Select a Test ID that uses voltage requiring the power pack, or create one that does.

4) Click on the configuration button to the right of the name of the DC test desired. The

DC Tests configuration window will appear.

5) Adjust the voltage required so that HiPot voltage is at least 2000 volts.

6) Enable the power pack by checking the Enable Power Pack box under the HiPot test parameter column. An error message will appear if a voltage below the minimum for the power pack is programmed after the Enable Power Pack box is checked.

NOTE

An error message will appear on the Baker AWA-IV screen if the power pack option is selected and a power pack is not connected.

7) Turn the Voltage Output Control knob on the power pack to MIN (full counterclockwise).

8) Select one of the HiPot settings on the power pack Function knob. When the HiPot

100 m Amp/Division setting is chosen, a loud relay noise will be heard.

9) Connect the power pack leads to the motor as shown in the table below.

Table 3. Baker PP30 motor connections for Surge 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. Internal connections during HiPot testing.

Test Select

Position

Test

Lead 1

Test

Lead 2

Test

Lead 3

Ground

Lead

Black Braid

HiPot Hot Open Open Ground Motor frame or station ground

10) Ensure that the correct test is displayed on the Baker AWA-IV screen.

11) Start testing by pressing the power pack’s test button (or footswitch) and slowly raise the voltage using the power pack’s Voltage Output Control knob. Test results should immediately be visible on the Baker AWA-IV screen. If not, recheck the test lead connections and all the switch settings. Also, ensure that the interconnect cables have been attached and are secure.

12) Continue to hold the test button (or footswitch) for the duration of the test. Have

HiPot setting at 100 m A/Div to start. Change the micro-amps per division switch as needed to increase the sensitivity of the data acquisition during test.

13) For example, if target voltage is needed, and at 100 m A/Div you see less then 50 m A of leakage current, it is best to switch the power pack to 10 m A per division for better accuracy. If less than 5 m A is leaking at 10 m A per division, switch to 1 m A per division for best accuracy. (This can be switched during the test).



Figure 127. Setting up DC HiPot test for power pack.

14) When the test Time Remaining clock runs down to 00:00, a message dialog will appear telling you that the motor needs to be discharged. Continue to hold down the test button (or footswitch) until instructed to release it.

15) When testing completes, release the test button (or footswitch) of the power pack and return the Voltage Output Control knob to its minimum setting.

16) Click on the Close button 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 completely discharge before disconnecting the test leads. The recommended practice is to discharge the winding for a duration of at least four times the duration of the DC HiPot test for high-voltage windings.

NOTE

For HiPot operation of the Baker AWA-IV 12kV host analyzer alone, the host analyzer and the power pack must both be powered up.



Conducting Surge tests with the Baker PP30 three-phase test lead power pack

1) After setting up the power pack and analyzer, on the Baker AWA-IV, select the motor to be tested from the Explore tab.

2) Click on the Tests tab to get to the main testing screen.

3) Select a Test ID that uses a voltage requiring the power pack, or create a test that does.

4) Click on the test configuration button at the end of the Surge test row. The Surge

Test setup window will appear.

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 power pack is programmed after the

Enable PP box is checked.

7) Click on the Pause between Leads button in the Surge Test setup window.

Figure 128. Setting up Surge test for power pack.

8) Turn the power packs’s Voltage Output Control know on the power pack to MIN (full counterclockwise).

9) Select the Surge test using the Function knob on the power pack.



10) If you haven’t already done so, connect the power pack leads to the motor as shown in Table 8 above. The following table shows the internal lead connections during

Surge testing when you move the Test Select switch to test each phase.

Table 5. Internal connections during Surge testing.

Test Select

Position

Test lead 1

Test Lead 1 Test Lead 2 Test Lead 3 Ground Lead Black Braid

Test lead 2

Hot

Ground

Ground

Hot

Ground

Ground

Ground

Ground

Motor frame or station ground

Test lead 3 Ground Ground Hot Ground

11) To start the Surge test, click 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 the Lead 1 button.

Figure 129. Surge Test start message.

12) After clicking on the Lead 1 button, you will see a message instructing you to move the Test Lead Selector switch on the power pack to the Lead 1 position. Adjust the switch as needed, then click on OK to continue.

Figure 130. Surge Test lead selection message.

13) Next, you will see a message instructing you to press the power pack’s Test button to begin testing lead 1.



14) Press and hold the Test button, and use the power pack’s Voltage Output Control knob to set the waveform to the desired voltage level.

Figure 131. Setting the voltage and waveform using the voltage output control knob.

15) When you have reached the voltage level and the software completes its test, a message dialog will appear 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 through the process as noted.

17) When you have completed testing all three phases, click on the Close button to return to the Main window, Tests tab.

18) Click on the yellow Save Results button to save your test results.



Testing with the Baker PP24 single-phase test lead power pack

The Baker PP24 power pack is supplied with single-phase test leads. The leads include one red cable and three black ground cables. All have insulating jackets and are rated at 60kV DC.

A black braided cable is also provided to connect the power pack to the motor frame or station ground. When needed during testing, you must manually move the red (hot) test lead between the different leads of the motor to energize the specific lead targeted for each test.

Conducting DC tests with the Baker PP24 single-phase test lead power pack


2) Click on the Tests tab to get to the main testing screen then select a Test ID that uses a voltage requiring the power pack or create one that does.

3) Click on the test configuration button at the end of any DC Tests row. The DC Tests setup window will appear.

4) Adjust the voltage required so that the HiPot voltage is at least 2000 volts.

5) In the DC Tests setup window, check the Enable Power Pack box. An error message will appear if a voltage below the minimum for the power pack is programmed after the Enable Power Pack box is checked.

6) Connect the power pack leads to the motor as shown in the following table.

Table 6. Connections for HiPot testing.

Red (Energized) Black 1 (Grd) Black 2 (Grd) Black 3 (Grd) Black Braided (Grd)

Motor phase A Open/not connected

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 pack Function knob. When the

HiPot 100 m Amp/Division setting is chosen, a loud relay noise will be heard.

9) Ensure that the correct test is displayed on the analyzer’s screen.

10) Start testing by pressing the power pack’s Test button (or footswitch) and slowly raise the voltage level using the power pack’s Voltage Output Control knob. Test results should immediately be visible on the analyzer’s screen. If not, recheck the test lead connections and switch settings. Also, ensure that the interconnect cables have been attached and are secure.

11) Continue to hold the Test button for the duration of the test.

12) Set the micro-amps per division switch to HiPot 100 m A/Div to start. Change the switch as needed to increase the sensitivity of the data acquisition during test.

For example, if target voltage is needed, and at 100 m A/Div is less then 50 m A of leakage current, it is best to change the power pack Test Select switch to 10 m A per division for better accuracy. If less than 5 m A is leaking at 10 m A per division, switch to 1 m A per division for best accuracy. (In this case, it is okay to switch during the test).

13) When the test has completed, release the Test button of the power pack and return the Voltage Output Control knob to its minimum setting.

14) If test results should be saved, click the yellow Save Results button in the Main window, Tests tab.



Conducting Surge tests with the Baker PP24 single-phase test lead power pack


2) Click on the Tests tab to get to the main testing screen then select a Test ID that uses a voltage requiring the power pack, or create a test that does.

3) Click on the test configuration button at the end of the Surge Test row. The Surge

Test setup window will appear.

4) Adjust the voltage required so that surge voltage is at least 5000 volts.

5) In the Surge Test setup window, check the Enable Power Pack box. An error message will appear on the Baker AWA-IV screen if the power pack option is selected and accepted and no power pack connection is detected.

6) Click on the Pause between Leads button in the Surge Test setup window.

7) Turn the Voltage Output Control knob on the power pack to Min (full counterclockwise).

8) Select the Surge test using the Function knob on the power pack.

9) Connect the power pack leads to the motor as shown in the following table.

Table 7. Single-phase leads; Surge test connections.

Red (Energized) Black 1 (Grd) Black 2 (Grd) Black 3 (Grd) Black Braided (Grd)

Motor phase A

Motor phase B

Motor phase B Motor phase C Motor frame

Motor phase A Motor phase C Motor frame

Motor frame or station ground

Motor phase C Motor phase B 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 erroneous if the coil ground is used instead of the frame grounding.

11) To start the Surge test, click 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 the Lead 1 button.

12) After selecting the lead to test, start testing by pressing the power pack’s Test button

(or footswitch) and slowly raise the test voltage using the power pack’s Voltage

Output Control knob. Test results should immediately be visible on the analyzer’s screen. If not, recheck the connections and switch settings. Also, ensure that the interconnect cables have been attached and are secure.

13) Continue to hold the Test button (or footswitch) for the duration of the test.

14) When the test has completed, release the Test button (or footswitch) on the power pack and return the Voltage Output Control knob to its minimum setting.

15) Switch the leads according to the table above to surge different motor leads. Repeat steps 11–15 until all phases have been tested.

16) When you have completed testing all leads, click on the Close button.

17) If test results should be saved, click the Save Results button on the Main window,

Tests tab.



CAUTION

Always allow sufficient time for the test winding to completely discharge before disconnecting 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.


9 Using the Baker ZTX with Baker AWA-IV analyzers

The Baker AT101 ZTX accessory combines hardware and software to help you determine an armature’s insulation integrity. The hardware includes the impedance-matching transformer and fixtures. The software facilitates the acquisition of waveforms and comparison to a reference.

The 6 kV, 12 kV, and 12 HO models can be used with the Baker ZTX accessory to test armatures. However, not all 6 and 12 kV models are properly configured to support this accessory. All such analyzers built since February 2009 will work with the Baker ZTX accessory. Most analyzers built since December of 2007 can be modified at the factory to work. Please contact the customer service department if you are interested in having your unit modified to work with the Baker ZTX accessory.

The software version of the unit must also be upgraded to 4.5.0 or higher. To determine if your analyzer is capable of using the Baker ZTX accessory, contact the customer service department.

Principles of armature insulation testing

Armatures from DC motors are wound in many different ways, and some are rather complicated. However, testing armature insulation is actually very simple. The insulation of the copper to the steel or ground wall is evaluated using the HiPot test, while the turn insulation 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 slots. A unit can also have

“equalizer bars” that connect opposing commutator bars, which are also isolated from the steel armature core.

The armature winding consists of a few turns of high capacity conductors that span slots in the rotor and connect to the commutator bars. These conductors are insulated from each other with the “turn insulation.” Due to vibration, thermal expansion, chemical attack, and other factors the turn insulation can degrade, resulting in turns shorting to each other.

Because the inductance of armature winding turns is so low, a special impedance-matching transformer is used to convert the output of a Baker AWA-IV surge tester to voltage and current levels desirable for surge testing low-inductance armature windings. Additionally, armature windings are all in parallel, further reducing the bar-to-bar inductance, making the impedance-matching transformer all the more important.

A change in the surge waveform of a shorted coil as compared to a reference waveform indicates an arcing or shorted armature winding.

Typically, the reference waveform is acquired from the first bar (coil) tested. Waveforms collected from subsequent bars are compared to the reference bar. According to EASA guidelines, waveforms with a five percent or greater difference should be considered suspect.

Using the Baker ZTX with Baker AWA-IV analyzers

Connecting Baker AWA-IV to the Baker ZTX accessory

1) Connect the AUX cable to the AUX/PP connector on the front panel of the Baker

AWA-IV and the AUX connector on the front panel of the Baker ZTX.

Figure 132. Connect AUX 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/L2/L3

LEADS receptacle on the back of the Baker ZTX.

Figure 133. Connect AWA test leads to ZTX.



4) Connect the ATF-5000 armature testing accessory to the FOOT SWITCH connector on the front panel of the Baker ZTX.

5) Connect the ATF-5000 surge and sense cables to the Baker ZTX surge and sense cables (rounded connectors).

6) Use the thumbwheel to adjust the width of the bar-bar armature test accessory to fit the width of two adjacent bars on the armature being tested. ATF-5000 contacts 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 accessories, such as SKF test probes, can also be used during bar-to-bar testing.

Armature preparation

1) Identify the bar on the armature to be used as “Bar 1.”

2) It is also helpful to label every 5th or 10th bar.

3) Insulating tape works well for labeling the bars.



Configuring a Surge test for armature bar-to-bar testing

1) First, you must create a Motor ID for the armature to be tested. You can easily do this by starting with the Motor ID for the armature’s motor, allowing you to re-use most of the nameplate information already entered. This information will also help you identify the target voltage needed for your armature test.

2) Save the new Motor ID with a name similar to the whole motor, but with “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 “Arm 250VDC.”

After creating the new Test ID, the Tests tab will look similar to the example below.

4) Click on the Off button in the Surge Test section to turn Surge test on.

Figure 135. Test set up.

5) Click on the test configuration button at the end of the Surge Test section. The

Surge Test setup window will appear.



6) Enter a value for the Surge Voltag e based on your company and/or standards body recommendations for the motor armature being tested. In this example, we use

500 volts.

7) Ensure that the P-P EAR box is checked.

8) Ensure that the Enable PP box is not checked, then check the ARM box as 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 setup window as shown in the example below.

NOTE

If the ARM check box is not visible, the Baker AWA-IV being used is not configured to work with a Baker ZTX.



10) Ensure that the Target Voltage is set as needed for your armature.

11) Set the Volts/Div value low enough to allow you to easily view the waveform. If left at Auto , the analyzer will auto-range for the reference wave, but set the scale for subsequent tests.

Figure 137. Surge Test window showing tester is Baker ZTX compatible.

12) Change the reference-to-bar EAR% 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 off Test ID editing.

NOTE

The bar-to-bar surge test is a manual test that cannot be performed using the automatic features of the Baker AWA-IV.

Complete procedures for creating Test IDs and Motor IDs are provided earlier in this manual.



Running the manual surge test using the Baker ZTX

NOTE

In most applications, you will need help from another person to complete at least the first part of this test process: obtaining the reference waveform. One person will operate the fixture on the armature while the other operates the software.

CAUTION

Ensure that both operators clearly understand the process and how to use the software. The fixture/probe operator must know how to properly use the

ATF-5000 or test probes to avoid damage to the test equipment or the unit under test.

Exercise caution when performing the test to avoid injury from electrical shock, or damage to the test equipment or unit under test.

1) For this example, a new Motor ID for the armature, along with a new Test ID, have been created. For your application, ensure that you have selected the proper Motor

ID and Test ID for your armature.

2) From the Tests tab, ensure that the selected Test ID has the Surge test turned on and is labeled “Surge Test Using 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 ensure that the voltage output control knob on the AWA front panel is at zero;—turned fully counterclockwise.

5) The armature operator will position the test fixture (or probes) on the first bar and the second bar (adjacent to the right); bar 1 will be the reference bar. Bars are tested in a progressing sequence of 1–2, 2–3, 3–4, and so on.

6) When both operators are ready, the armature operator will hold down one of the test button on the ATF-5000 (or footswitch if using probes), then the AWA operator will ramp the voltage to the desired level.

7) After the first bar is tested and you are satisfied that you have a good reference waveform, the AWA operator will click on the Set Ref button. This establishes the reference for the remainder of the test and the tester’s voltage level.

8) No more ramping of the voltage will be necessary; do not move the voltage knob.



9) In the following example, the target waveform is acquired from bar 1, so the Set Ref button is pressed.

Figure 138. Reference wave EAR.

10) A dialog box will appear with a warning that you that the voltage will lock at and start at the target voltage level for all subsequent test, overriding the zero-volt interlock feature.

Figure 139. Zero start override warning message.

11) Move the test fixture to the second bar (2–3).

12) Press the test button 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 reference-to-bar EAR value will be displayed in the Ref Bar EAR field.

13) If the EAR percentage is greater than the tolerance, the field background will turn red indicating a failed test. If the EAR percentage is under or equal to the tolerance, the background of the Ref-Bar EAR box will be white, indicating a passing test.



14) When you are satisfied with the waveform, release the fixture’s test button or footswitch. The EAR percentage will be saved 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.

15) Up to three additional waveforms can be saved during the testing process. If a bar fails or is of interest, click on one of the Save button in the Save Waveforms section at the top of the screen and that waveform will be saved along with its bar number; otherwise, only the reference-to-bar EAR percentage for the bar will be saved.

16) Continue to move the test fixture to the next bar and repeat steps 10–14 for each bar until all bars have been tested. A maximum of 1,024 bars can 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 to the bar number, and retest as needed. Retesting will overwrite the previous data for that bar.

18) The Total Bars Tested number gives you the number of the last bar tested. Add one to that number to resume testing where you left off.

19) After all bars have been tested, click the Close button. The software will return you to the Main view Tests tab, which will look similar to the example below.

20) 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.

Figure 140. Main view Tests tab after testing; Save Results.



Reviewing test results/data

1) Click on the Data tab, Surge view (bottom tab) to review the test results. The graph will display the reference waveform in black and up to three saved waveforms in red, blue, and yellow.

2) The Surge view will also display the saved bars number, peak voltage, and referenceto-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 bar graph of the reference-to-bar EAR’s of all bars tested.

Figure 141. Surge test results.



Figure 142. Bar-to-Bar EAR graph.

This graph has zoom capabilities that allow you to look more closely at a section of bars.

5) Hold the left mouse button down and drag the cursor 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 on the Reset button and all bars will be displayed.



Printing reports

To print reports for bar-to-bar surge data, click on the printer icon on the upper left of the

Main window. The Report Generator window will appear.

1) Select the filter(s) you want to use.

2) Check the Surge-Comparison and EAR Graph boxes.

3) Select the output you want to use.

4) 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 taken using the Baker ZTX. It then prints the appropriate graphs for the results and reports chosen.

Figure 143. Example report generated using parameters set above.



Generating CSV files

The report generator provides you with the option to print the reference-to-bar EAR values to a comma separated values (CSV) file for easy import in to a spreadsheet application. To utilize this feature:

1) Start the report generator by clicking File , Print or by clicking on the Print icon in the top left of the Main 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 Text File button. This will open a File Save dialog box.

5) Enter the name of the CSV file for data output. Click the Save button.

6) The selected records will be written to the file named with the extension of .txt.




Appendix A — Baker AWA-IV troubleshooting

Please review this section before you contact SKF technical support, or return the unit.

Self-help and diagnostics

Problems in testing often crop up. If you are experiencing a problem and believe it might be with the analyzer, please take the following steps before calling or returning the unit.

By performing these procedures and having the requested information available, SKF technical support will be able to better assess your situation and provide the appropriate response. You can contact SKF technical support toll-free at 800-752-8272 or 970-282-

1200 for assistance. You can also send an email to [email protected] with questions or to request assistance.

Repair parts

WARNING

Electrical shock hazard can be present 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 minimize safety hazards.

Do not modify or repair test leads in any way. Defective, damaged, or broken test leads must be replaced with factory-authorized parts to ensure safe operation and maintain performance specifications.

Step #1: Basic information

Record all basic analyzer information including:

• Model number

• Serial number

• Product number

• Software version number

NOTE

All information above except for software version number is located on the rear panel product label. Software version can be found by starting the software and clicking on the Help-About Baker AWA-IV… menu item. If the analyzer has special options installed, please note these. Any analyzer information derived is helpful! A great tool would be a printout or sketch of the waveforms displayed on the analyzer.

Baker AWA-IV troubleshooting

Step #2: Applications or service problem?

Generally, if a problem is noted only when testing a specific motor/generator or other coil type, then applications would be involved. See “Applications: What to do first” Please call the sales department for applications assistance.

If the problem is not 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 the section on common application problems. Please have basic information about the analyzer and specific information about the motor being tested available when calling or faxing to assist sales/support personnel in determining a solution to the problem.

Examples:

• Hp rating

• kW rating

• RPM rating

• Operating voltage and current

• How the item being tested is wound and/or number and type of coils

• Application of motor/generator

In short, all information from the motor nameplate would be helpful. A great tool is a printout or sketch of the waveforms displayed on the analyzer.

If a FAX is available, send a draft to 970-282-1010, attention: 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 apparatus under test.

1.1 The test motor may be too large for the analyzer being used. The impedance of the windings may be too low.

1.2 The Baker AWA-IV may be at fault in this case. Do not continue testing until you contact the SKF product service department.

2) Separation of compared surge wave patterns is seen when surge testing knowngood coils, or brand new motors or windings. Often, separation is seen in all three comparisons for three phase motors, but to varying degrees.

2.1 Generally, this is caused by unbalanced impedance in windings, which is inherent to the design. It most commonly occurs in basket or concentric wound motors. The phases are not magnetically balanced due to different coil lengths.

2.2 When acceptance testing, waveforms that are separated because of improper turn counts, misconnections, or reversed winding groups may be seen.

2.3 This condition may also be seen in DC fields or rotating poles. Coils being compared must be tested in identical configurations.



2.4 On very large equipment, slight differences in capacitance to ground may be the cause. At low voltage levels, begin the test again with the black ground lead removed from the motor frame. If the separations disappear, the problem was capacitance to ground. Be sure the winding has passed the DC tests before doing the Surge test.

3) There is no dampened sinusoidal wave pattern on the display when testing a coil.

The wave pattern rises on the left and then slowly drops as it trails off to the right of the screen. It may or may not cross the zero/base line.

3.1 The coil under test is probably too high an impedance to get a good working pattern. The coil may be very high in resistance.

3.2 A 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 lead with the other hand. A broken lead will stretch, whereas a good lead will not.

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 against each other.

• Never come in contact with the item being tested and the test leads, or with the analyzer and the item being tested.

• Never attempt a two-party operation.

• Never attempt a burn-out of a detected fault with the analyzer.

• Always know what test is being performed and when.



Service: What to do first

Because history has shown that several simple solutions that do not require return of a unit may arise, please perform the following checks.

Open condition display

Note the figure below. Is the surge waveform like this?

Figure 145. Open condition.

If yes, the unit may have at least one broken test lead causing an open condition. In most cases, the test lead that is under test and gives this pattern is the broken lead.

Verify this by pulling on the book/clip assembly of the lead. A broken test lead will stretch. If it does not, repeat this procedure at one foot intervals for the length of the lead. If the leads of the 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.

1.1 The item being tested is in fact faulty and has either low insulation resistance or open connections.

1.2 The Baker AWA-IV has an internal problem.

1.3 The analyzer has a test lead problem as shown above for an open condition.

Disconnect the test leads from the motor and isolate the analyzer from any grounded surface.

Reduce the output to minimum and attempt a HiPot test with an open lead condition. Your display should indicate a rising voltage bar. The current bar may rise slightly, but fall back to zero when the output increase is stopped.



NOTE

It is not necessary to run the output control at a high level to determine if the Baker

AWA-IV is working properly.

If the display still shows no voltage bar, call the service department. Use a meter to confirm the insulation resistance of the device being tested.

Current bar operation can be tested by shorting test lead 1 to the ground lead. Under this condition, the voltage bar will not move off the zero line and the current bar should rise very rapidly and activate the HiPot overcurrent trip warning light (HiPot trip). If the HiPot Trip light does not light, check for open test leads at either test lead 1 or the ground lead (see “Open ground check” below). If the problem persists, contact the service department.

HiPot overcurrent trip check

1) Either the HiPot trip lamp does not activate under known shorted conditions, or it will not go out when test is discontinued.

Call the service department immediately for assistance. Please record information off the unit and the specific problem prior to calling.

Open ground check

The open ground 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 source is unknown?

• Is the unit being operated on a scope cart that has its own outlet or power source?

• Is the unit being operated using a two-wire extension cord?

• Is the unit being operated on a transformer-isolated circuit?

If you answer “yes” to any of these questions, the unit is probably operational and indicating that there is open AC line ground connection.

For the first three questions above, use an outlet analyzer to ensure proper wiring connections to the outlet.

Limited output surge waveform

The display shows a limited output (amplitude) surge waveform. The display rises normally, but stops at some point. Alternatively, you must continually increase the output control for successive tests to achieve the same output test amplitude.

Call the service department immediately for assistance on this or any other abnormal condition noted. Please record basic information from the analyzer and the specific problem prior to calling.



Proper storage of leads/unit

After the analyzer has been correctly shut down, the high-voltage and resistance leads can be placed back into the nylon bag with the power cord. This can be carefully placed on top of the touchscreen and the lid closed for storage. Not placing the leads in the nylon, bag and putting them directly onto the touchscreen can break or damage the screen. If the screen is damaged, the unit will not operate properly and it will have to be sent to SKF for replacement.

Although these units come with a comprehensive one-year warranty, exterior damage of this type is not covered.

Take care to keep the unit dry. The analyzer should not be stored in any location where water entry to the analyzer can occur. Humidity will also affect the operation of the analyzer.

Checking test leads for broken sections

Either prior to using the analyzer or at least once a month, inspect each test lead for broken sections. If the analyzer has a broken lead, it will not work properly and could yield erroneous results. The typical spots where leads break are within the first six inches from the analyzer panel strain-reliefs and 12–18 inches from the clips. There are two methods to check for breaks in the leads: a manual check and an overcurrent trip test.

Manual break check

1) Inspect the 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 inches from the strain relief on the analyzer.

4) Steadily, pull the lead. If the lead stretches, it is broken. If it does not have any give, it is good.

Overcurrent trip test

The black ground lead is the most commonly broken lead. This is an easy test to verify if the black lead is broken.

1) Connect all leads together (clip to clip) (three red, one black ground).

2) Place analyzer in either Meg-Ohm or DC HiPot mode. Initiate test.

3) If the analyzer immediately shows an overcurrent trip, the black test lead is good. If the analyzer continues to ramp up to the test voltage, the black test lead is broken.

Open circuit test to verify analyzer operation

While doing periodic testing, there are some instances that the analyzer will immediately trip when first initiating testing. When this occurs, there is generally some question by the operator if the motor is truly bad or if the analyzer is operating correctly. A simple open circuit test verifies analyzer operation.

1) Unhook all leads from the motor being tested.

2) Store all leads in a safe place: on the floor, over the edges of a plastic trash can, and so on. Ensure that the test clips do not touch.

3) Place the black lead away from the red leads.



4) Initiate either a Meg-Ohm or a DC HiPot test.

5) If the analyzer is operating correctly, it will ramp up to the test voltage with minimal leakage current and will not overcurrent trip. If the analyzer is not operating correctly, it will overcurrent trip immediately as it did when it was attached to the motor.

6) If the analyzer is operating correctly, reconnect to the possible bad motor and retest.

If it is not operating correctly, contact 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 or spam blockers, screen savers, virus detectors or wireless internet software to the analyzer. It will corrupt testing procedures and operations. Many of these types of software packages, when installed on the analyzer, will continue to poll/ use CPU resources of the computer even when not open on the desktop, creating conflicts.



Warranty return

Please review the warranty notes and shipment sections at the beginning of this manual before sending your analyzer to SKF for warranty repair.

The warranty-return form below must be filled out and returned with the analyzer to obtain warranty service. This form will help to ensure that SKF service personnel can identify the problem, and quickly repair your unit and return it to you.

Warranty return form

Please copy and fill out all the following information and return this form with the analyzer.

Make a copy of all records before sending the analyzer to SKF.

NOTE: Be sure to follow the guidelines for shipping when sending the analyzer.

Company Name:______________________

Name: ______________________________

Mailing Address:_______________________

Shipping Address:____________________

Phone Number: _____________________

Fax:______________________________

From the name plate on the back of the analyzer:

SKF Product Number: _________________________________

Model Number: ____________________________________

Serial Number: ____________________________________

Software Version #: ____________________________________

Description of the problem:

Please give as much information as possible (what is not working, when it happened, what was being tested, any unusual noises, and so on) even if you already talked to someone by phone. Use the back of the copy of this form if necessary.

Person contacted at SKF EMCM: ____________________________________________________

Ship the analyzer to:

SKF USA, Inc. EMCM

4812 McMurry Avenue


Attn: Service Manager


Appendix B — Technical specifications and applicable standards

Calibration information

New Baker AWA testers are calibrated at the manufacturing facility before shipping.

Calibration is recommended annually to ensure continued optimum performance.

For more information, please contact SKF Condition Monitoring Center, Fort Collins (SKF USA) for current calibration information. You may also contact the Service department at (970)

282-1200 or (800) 752-8272.

Baker AWA-IV 2 kV and 4 kV tester specifications

Table 8. Surge test specifications.

Parameter

Output voltage

Max output current

Pulse energy

Storage capacitance

Sweep range

Volts/division

Repetition rate

Voltage measurement and accuracy

Baker AWA-IV 2 kV

0–2160 volts

200 amps

.2 joules

.1F

2.5–200μS/Div

500/1000/2000/ 3000

5 Hz

+/– 12%


0–4250 volts

400 amps

.9 joules

.1μF

2.5–200μS/Div

500/1000/2000/ 3000

5 Hz

+/– 12%

Table 9. DC High Potential (HIPot) test specifications.

Parameter

Output voltage

Max output current

Current resolution

Overcurrent trip settings

Full scale voltage and current measurement and accuracy

Meg-ohm accuracy

Max Meg-ohm reading


0–2160 volts

1000 μamps

.1/10/100/1000 μamps/ division

1/10/100/1000 μamps

+/– 5%

+/– 10%

50,000 MΩ


0–4250 volts

1000 μamps


1/10/100/1000 μamps

+/– 5%

+/– 10%

50,000 MΩ

Technical specifications and applicable standards

Table 10. Physical characteristics.

Parameter

Weight

Dimensions (W x H x D)

Power requirements

Baker AWA-IV 2kV

24 lbs.

15 x 8 x 8 inches

85–264VAC 50/60 Hz @

500 watts or more

Baker AWA-IV 4kV

24 lbs.

15 x 8 x 8 inches

85–264VAC 50/60 Hz @

500 watts or more

Table 11. Accuracy of measurements—Coil resistance test. Four-wire Kelvin method resistance test

Range

*10Ω–100Ω

2Ω–20Ω

.2Ω–2Ω

.05Ω–.6Ω

.005Ω–.07Ω

.001Ω–.01Ω

Resolution

.1Ω

.1Ω

.05Ω

.005Ω

.0002Ω

.0001Ω

* Above 100Ω is reported as a potentially open circuit.

Full-scale accuracy

+/– 5%

+/– 5%

+/– 5%

+/– 5%

+/– 5%

+/– 5%

Table 12. Testing accuracy for HiPot measurements.

Range

100 μA/Div

10 μA/Div

Approximate maximum measurable current

900μA

90μA

1 μA/Div

.1 μA/Div

9μA

.9μA +/– .045μA

Resolution

+/–5% from

9μA–90μA

+/–5% from

.9μA–9μA

+/–5% from

.1μA–.9μA


+/– 5%

+/– 5%

+/– 5%

+/– 10%

Table 13. Voltage measurement accuracy—Surge test.

Range

500V/Div

1000V/Div

2000V/Div

Resolution

+/–12%

+/–12%

+/–12%



Baker AWA-IV 6 kV, 12 kV, and 12 kVHO tester specifications

Table 14. Surge test specifications.

Parameter

Output voltage

Baker AWA-IV 6 kV Baker AWA-IV 12 kV Baker AWA-IV 12 HO

0–6000 Volts

Max output current 350 amps

0–12000 Volts

400 amps

0–12000 Volts

400+ amps

Pulse energy .72 joules

Storage capacitance .04μF

Sweep range

Volts/division

2.5–200 μS/Div

500/1000/2000/

3000

Repetition rate

Voltage measurement and accuracy

5 Hz

+/– 12%

2.88 joules

.04μF

2.5–200 μS/Div

500/1000/2000/

3000

5 Hz

+/– 12%

7.2 joules

.1μF

2.5–200 μS/Div

500/1000/2000/

3000

5 Hz

+/– 12%

Table 15. DC High Potential (HIPot) test specifications.

Parameter

Output voltage

Overcurrent trip settings


0–6000 volts 0–12000 volts 0–12000 volts

Max output current 800 μamps

Current resolution .1/1/10/100

μamps/ division

1/10/100/100

μamps

800 μamps


1/10/100/100

μamps

800 μamps


1/10/100/100 μamps

Full scale voltage and current measurement and accuracy

+/– 5%

Meg-ohm accuracy +/– 10%

Max Meg-ohm reading

50,000 MΩ

+/– 5%

+/– 10%

50,000 MΩ

+/– 5%

+/– 10%

50,000 MΩ

Table 16. Physical characteristics.

Parameter

Weight

Dimensions

(W x H x D)


40 lbs.

16 x 8 x 21 inches 16 x 8 x 21 inches

Power requirements 85–264VAC 50/60

Hz @ 2.5 amps

Resistance measurement range

.001Ω–50Ω

40 lbs.

85–264VAC 50/60

Hz @ 2.5 amps

.001Ω–50Ω

40 lbs.

16 x 8 x 21 inches

85–264VAC 50/60 Hz

@ 2.5 amps

.001Ω–50Ω



Table 17. Accuracy of measurements—Coil resistance test. Resistance balance test (high-voltage leads).

Range

*10Ω–50Ω

2Ω–20Ω

.030Ω–2Ω

**.000Ω–.4Ω


+/– 5%

+/– 5%

+/– 5%

+/– 5%


**Balance test is not rated below .500Ω (for high-voltage test leads).

Table 18. Accuracy of measurements—4-wire kelvin method resistance test. (Use separate test leads).

Range

*10Ω–50Ω

2Ω–20Ω

.2Ω–2Ω

.05Ω–.6Ω

.005Ω–.07Ω

.001Ω–.01Ω



+/– 5%

+/– 5%

+/– 5%

+/– 5%

+/– 5%

+/– 5%

Table 19. * Testing accuracy for HiPot Measurements.

Range

100 μ A/Div

10 μ A/Div

1 μ A/Div

Approximate maximum measurable current

900 μA

90 μA

9 μA


+/– 5%

+/– 5%

+/– 5%

Table 20. Voltage measurement accuracy—Surge test.

Range

500V/Div

1000V/Div

2000V/Div

3000V/Div

Accuracy

+/–12%

+/–12%

+/–12%

+/–12%



Applicable standards

• EASA Standard AR100-1998 Recommended Practice for the Repair of Rotating

Electrical Apparatus

• 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 95-1977 Guide for Insulation Maintenance of Large AC Rotating Machinery

• IEEE 112-1991 Test Procedures for Polyphase Induction Motors and Generators

• IEEE 113-1985 Guide on Test Procedures for DC Machines

• IEEE 115-1983 Test Procedures for Synchronous Machines

• IEEE 429-1972 Evaluation of Sealed Insulation Systems for AC Electric Machinery

Employing Form-Wound Stator 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-

Voltage Machine s

• IEEE 522-1992 Guide for Testing Turn-To-Turn Insulation on Form-Wound Stator

Coils for Alternating-Current Rotating Electric Machines

• NEMA MG1-1993 Motors & Generators

Reprints or EASA standards are available from: www.easa.com

1331 Baur Boulevard

St. Louis, MO 63132

Phone: 314-993-2220

FAX: 314-993-1269

Reprints of IEC standards are available from:

International Electrotechnical Commission (IEC) www.IEC.ch

Reprints of IEEE standards are available from:

IEEE Customer Service

445 Hoes Lane

P.O. Box Piscataway, NJ 08855-1331

Phone: 1-800-678-IEEE

Fax: 908-981-9667 www.ieee.org



Reprints of NEMA standards are available from:

National Electrical Manufacturers Association (NEMA)

Global Engineering Documents

Phone: 1-800-854-7179

International: 303-379-2740


Appendix C — Database definition

Version 4.0 database definition

The Baker AWA-IV database is an Access 97 database (.mdb). It can also be converted to an

Access 2000 database and be used by the analyzer. The Access database is divided into several tables.

• The motor information and test results data is contained in the following tables:

MotorID, TestResults, TestResultsParameters, TestResultsPI, TestResultsPrgHiPot, and SurgeWaveform.

• The testing criteria used to run the tests are contained in the following tables: TestId,

TestIdPrgHiPot, and RefSrgWaveform.

• Two addition tables are used, one is the DatabaseInfo table and the other is the

Route table.

Nameplate table—(MotorID)

The MotorID table contains the nameplate information for each motor added to the database.

There is only one motor record per motor. The motor_key is the primary keyed field. It is automatically 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 motor_key tree_level_1 tree_level_2 motor_id

Type

Long integer

Text (25)

Text (25)

Text (30)

Description

Automatically generated number used as the primary key.

First level used in the tree view. Motor location 1 user defined field label, defaults to Location.

Second level used in the tree view.

Motor location 2 user defined field label, defaults to Building.

User entered Motor Identification value. It must be unique.

Manufacturer of the motor.

manuf manuf_type manuf_date_code model

Text (25)

Text (25)

Text (16)

Text (25) sn hpkw rpm voltage_rating voltage_operating

Text (25)

Single

Single

Text (16)

Single

Manufacturer’s nameplate date.

Manufacture’s Identification of model type.

Manufacture’s serial number.

Nameplate horse power or kilowatts.

Revolutions per minute (RPM).

Nameplate voltage ratings.

Name Plate Voltage used as a Voltage

Class.

Database definition

Field name amps_rating amps_operating frame insulation_class lockec_rotor_current locked_rotor_code service_factor enclosure freq_hz

NEMA_design_code

NEMA_nom_efficiency max_ambient_temp duty_cycle user_defined_description winding_config

Type

Text (16)

Single

Text (16)

Text (8)

Single

Text (4)

Single

Text (16)

Long integer

Text (4)

Short

Single

Text (16)

Text (64)

Text (8)

Description

Nameplate current (amps) ratings.

Operating current (amps).

Frame type code indicating dimensions.

Locked rotor current in amps.

Locked rotor current in amps.

A letter code that groups motors based on KVA/hp. (KVA code)

Factor when multiplied by hp, gives the allowable hp loading.

Classifies the motor as to its degree of protection from the environment and method of cooling.

Input frequency usually 50 or 60 Hz.

NEMA codes assigned to define torque and current characteristics of the motor.

This represents an average efficiency of a large population of like motors.

The maximum ambient temperature at which the motor can operate and still be within the tolerance of the insulation class at the max temperature rise in C.

Defines the length of time during which the motor can carry its nameplate rating safely.

User defined motor description field.

Wye or delta winding configuration.

Test results table—(TestResults)

The TestResults table has a test_resultno that is auto generated each time a test results record is added either after a test is performed or in the Application View of the AWA software.

Table 22. Field name descriptions.

Field name test_resultno motor_key testdate_time

Type

Long integer

Long integer

Date/Time

Description

Automatically generated number used as primary key. Foreign key in other test result tables.

Used as the foreign key. (Primary key of MotorID table). Links the test results to the Motor ID’s.

Time stamped at the time the test results are saved.


Database definition

Field name testid test_level_1 test_level_2 testfor testby baker_sn baker_tester_type baker_calibration_date baker_pp30sn use verthoriz starter start24h percentld roomno mcc app_volts1 app_volts2 app_volts3 app_amps1 app_amps2 app_amps3 repairno install basic rewind memo_used

Type

Text (25)

Text (25)

Text (25)

Text (25)

Text (25)

Long integer

Text (25)

Text (20)

Long integer

Text (25)

Text (16)

Text (16)

Text (16)

Text (4)

Text (25)

Text (25)

Double

Double

Double

Double

Double

Double

Text (16)

Text (8)

Text (8)

Text (8)

Yes/No

Description

Test ID used for this set of test results.

First level used in the tree view.

Motor location 1 user defined field label, defaults to Location.

Second level used in the tree view

Motor location 2 user defined field label, defaults to Building.

Enter the entity for which the motor is being tested.

Enter the person who is performing the test on the motor.

Serial number on the Baker AWA-IV being used for the test.

Type of Baker AWA-IV being used for the test. (AWA, D12R, and so on).

Last date that the tester was calibrated.

Serial number of the power pack, if any.

Enter how the motor is being used.

Enter vertical or horizontal mounting.

Motor starter type.

Number of starts per 24 hours.

Percent of load being applied.

Room number. Can also be used as a job number.

Motor control cabinet Identification.

Application phase 1 voltage.



Application phase 1 current.



Repair number.

Date the motor was installed at the current location.

Date when the motor had basic service.

Date the motor was last rewound.

Indicates a memo has been entered.


Database definition

Table 23. Temperature test results.

Field name temp_status temp_why_failed temp_temperature temp_degF_C

Type

Text (8)

Text (25)

Double

Yes/No

Description

Contains the status of the test, PASS or FAIL if a test has been performed or blank if no temperature test has been conducted.

Reason why motor failed (if it failed).

Temperature of motor, always stored as Celsius.

False if temp was entered as C. True if temp was entered as F.

Table 24. Resistance test results.

Field name resist_status

Type

Text (8) resist_why_failed resist_balance1 resist_balance2 resist_balance3 resist_12 resist_23 resist_31 resist_corrected1 resist_corrected2 resist_corrected3 resist_delatR_max resist_coil1 resist_coil2 resist_coil3 resist_corrected_coil1 resist_corrected_coil2 resist_corrected_coil3

Double

Double

Double

Double

Double

Double

Double

Double

Double

Double

Text (25)

Double

Double

Double

Double

Double

Double


Description

Contains the status of the test, PASS or

FAIL if a test has been performed or blank if no resistance test has been conducted.

If the motor failed, reason why.

Balance resistance for lead 1.



Lead 1 to lead 2 resistance.



Corrected resistance for lead 1.



Max delta resistance test tolerance.

Coil resistance for lead 1.



Corrected coil resistance for lead 1.



Database definition

Table 25. Meg-Ohm test results.

Field name

Meg-Ohm_status

Meg-Ohm_whyFailed

Meg-Ohm_voltage

Meg-Ohm_current

Meg-Ohm_Meg-Ohm

Meg-Ohm_IR_at_40C

Table 26. PI test results.

Field name pi_status

Type

Text (8)

Text (25)

Long integer

Double

Long integer

Long integer

Type

Text (8)

Description


FAIL if a test has been performed or blank if no Meg-Ohm test has been conducted.


Voltage used in Meg-Ohm calculations.

Current used in Meg-Ohm calculations.

Meg-Ohm value = voltage/current.

Meg-Ohms (insulation resistance) at 40 °C.

pi_whyFailed pi_voltage pi_da_ratio pi_ratio

Text (25)

Short integer

Double

Double

Description

Contains the status of the test, PASS or FAIL if a test has been performed or blank if no PI test has been conducted. (DA Only DPASS/DFAIL.)


Test voltage for PI test.

3-minute resistance value divided by

30-second resistance value.

10-minute resistance value divided by

1-minute resistance value.

Table 27. HiPot test results.

Field name

HiPot_status

Type

Text (8)

HiPot_whyFailed

HiPot_voltage

HiPot_current

HiPot_Meg-Ohm

HiPot_IR_at_40C

Text (25)

Long integer

Double

Long integer

Long integer

Description


FAIL if a test has been performed or blank if no HiPot test has been conducted.


Voltage at the end of test.

Current at the end of test.

Meg-Ohm value = voltage/current.

Meg-Ohms (insulation resistance) at 40

°C.


Database definition

Table 28. DC High Potential (HIPot) test results.

Field name Type surge_status Text (8) surge_whyFailed surge_peak_volt1 surge_peak_volt2 surge_peak_volt3 surge_ear1_2 surge_ear1_3 surge_ear_2_3

Text (25)

Short integer

Short integer

Short integer

Short integer

Short integer

Short integer

Description

Contains the status of the test, PASS or FAIL if a test has been performed or blank if no surge test has been conducted.


Peak voltage reached for lead 1.



Error Area Ratio lead 1 to lead 2.



Memo table—(Memo)

This table contains the memo if any that a user can fill out per test result.

Table 29. Memo table field descriptions.

Field name Type Description

Test_resultno Long integer Foreign key used to link test result records.

motor_key memo

Long integer

Memo

Motor key Identification key.

Memo field type containing the user entered text.


Database definition

Polarization Index Test Results table—(TestResultsPI)

The TestResultsPI table contains a record for a test result, only if a DA/PI test has been performed. Then a record containing the motor_key and same test_resultno for each step of the test is added to the table.

Table 30. DC High Potential (HIPot) test results.

Field name test_result_no piamps240 piamps300 piamps360 piamps420 piamps480 piamps540 piamps600 pires15 pires30 motor_key piamps15 piamps30 piamps45 piamps60 piamps90 piamps120 piamps150 piamps180 pires45 pires60 pires90 pires120 pires150

Type

Long integer

Double

Double

Double

Double

Double

Double

Double

Double

Double

Double

Double

Double

Double

Double

Long integer

Double

Double

Double

Double

Double

Double

Double

Double

Description

Foreign key used to link test result records.

Motor Identification key.

Current in micro amps @ 15 seconds.















Resistance in Meg-Ohms @ 15 seconds.








Database definition

Field name pires180 pires240 pires300 pires360 pires420 pires480 pires540 pires600 pi_current_1sec

Type

Double

Double

Double

Double

Double

Double

Double

Double

Memo

Description









Comma delimited field containing the current for each second 180 data , if it is a

DA only, or 600 if a full PI was run.


Database definition

Step Voltage test results table—(TestResultsPrgHiPot)

The TestResultsPrgHiPot table contains a record for a test result, only if a Step Voltage Test test has been performed. Then a record containing the motor_key and same test_resultno for each step of the test is added to the table.

Table 31. Step voltage table field descriptions.

Field name test_resultno motor_key step_order step_voltage step_time step_ramp_rate step_min_Meg-Ohm

Meg-Ohm_at_endstep current_at_endstep voltage_1sec current_1sec time_1sec

Type

Long integer

Long integer

Long integer

Long integer

Short integer

Short integer

Long integer

Long integer

Double

Memo

Memo

Memo

Description

Foreign key used to link test result records.

Motor Identification key.

Enumerator used to sort results in step order.

Voltage for the given test interval.

Length of step in seconds.

Not used at this time.

Minimum Meg-Ohms aloud for the step.

Meg-Ohm value at the end of the step.

Current in micro amps at the end of the step.

Comma delimited field containing the voltage for each second of the interval, including ramping voltage.

Comma delimited field containing the current for each second of the interval, including current during ramping of voltage.

Comma delimited field containing the times progression for each second of the interval, including time during ramping of voltage.


Database definition

Surge test results table—(SurgeWaveform)

The SurgeWaveform table contains a record for a test result. After a surge test has been performed, a record that contains the motor_key and same test_result for one test is added to the table. This record contains all three surge tests for a three-phase motor.

Table 32. Detailed surge test results.

Field name test_rsultno

Type

Long integer motor_key waveFormatVr xscale yscale microSecPerPnt voltsPerPnt wave1Full wave1Mid wave1Min wave1PrevFail wave1ppEAR wave2Full wave2Mid wave2Min wave2PrevFail wave2ppEAR wave3Full wave3Mid wave3Min wave3PrevFail wave3ppEAR

Long integer

Double

Short integer

Short integer

Double

Double

Description

Test result number (unique key ties to other test results).

Motor identification key.

Version of waveform record.

Scale index for the x-axis (micro seconds per division).

Scale index for the y-axis (volts per div).

Micro seconds per point (Not used ).

Volts per point (Not used at this time).

Full waveform for lead 1.

Middle waveform for lead 1.

Minimum waveform for lead 1.

Wave form before the failed waveform for lead 1.

Pulse-to-Pulse EAR for lead 1.












Database definition

Test results parameters table—(TestResultsParameters)

This table contains the test parameters used at the time of testing and is associated with the

TestResults records by the test_resultno field.

Table 33. Test results parameters table field descriptions.

Field name test_resultno

Type

Long integer test_mode temp_enabled resist_enabled

Meg-Ohm_enabled pi_enabled

HiPot_enabled prgHiPot_enabled surge_enabled

Text (15)

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Description

Foreign key automatically generated in the

TestResults Table.

Will contain one of the following values

AUTOMATIC, SEMIAUTOMATIC, MANUAL, or UNKNOWN.

Temperature test: 1=on; 0=off.

Resistance test: 1= on; 0=off.

Meg-Ohm test: 1=on; 0=off.

PI test: 1=on; 0=off.

HiPot test: 1=on; 0=off.

Step Voltage Test enabled: 1=on; 0=off.

Surge test: 1=on; 0=off.

Table 34. Test results parameters table; temperature test parameters field descriptions.

Field name temp_isAuto temp_degF_C

Type

Yes/No

Yes/No

Description

1=Manual; 0=Automatic.

1=F degrees; 0=C degrees.


Database definition

Table 35. Test results parameters table; resistance test parameters field descriptions.

Field name Type Description resist_no_leads Short integer # of leads (2 or 3) Used also in surge.

resist_deltaR_enabled resist_ deltaR_maxpercent resist_external_enabled resist_isAuto resist_4lead_test_enabled resist_correct_to_temp_enabled Yes/No resist_temp_correct_to Short integer resist_temp_correct_factor Double resist_target_coilRes_enabled Yes/No resist_target_coilRes

Yes/No

Short integer

Yes/No

Yes/No

Yes/No

Double resist_target_coilRes_tolerance Long integer

1=delta R used in pass/fail; 0=Not used.

Max difference in percent.

Always false 0=No external testing.

1=Automatic; 0=Manual

1=4 lead test enabled; 0=4 lead test disabled (Only disabled at this time)

Correct resistance 1=Yes; 0=No.

Defines the value that the temperature will be corrected to.

Default 234.5 for copper.

1=Coil resistance checking enabled;0=not enabled.

Coil resistance to compare tested value with.

Tolerance set for target coil resistance.

Table 36. Test results parameters table; Meg-Ohm test parameters field descriptions.

Field name

Meg-Ohm_test_voltage

Meg-Ohm_min_Meg-Ohm

Type

Short integer

Short integer

Meg-Ohm_test_time

Meg-Ohm_ramp_rate

Meg-Ohm_trip_level

Short integer

Short integer

Short integer

Meg-Ohm_discharge_multiplier Short integer

Meg-Ohm_PowerPack_enabled Yes/No

Description

Target voltage of test.

Minimum Meg-Ohm value.

Length of test.

Ramp rate.

HiPot trip value.

Number of minutes to discharge.

1=PP enabled; 0=No PP.


Database definition

Table 37. Test results parameters table; polarization index test parameters field descriptions.

Field name Type Description pi_test_voltage Short integer Target voltage of test.

pi_min_Meg-Ohm pi_min_ratio pi_ramp_rate pi_trip_level pi_da_only_enabled pi_revert_to_da_enabled pi_discharge_multiplier pi_PowerPack_enabled

Short integer

Double

Short integer

Short integer

Yes/No

Yes/No

Short integer

Yes/No


Length of test.

Ramp rate.

HiPot trip value.

1=DA only; anything else PI.



Table 38. Test results parameters table; HiPot test parameters field descriptions.

Field name

HiPot_test_voltage

Type

Short integer

HiPot_min_Meg-Ohm

HiPot_test_time

HiPot_ramp_rate

HiPot_trip_level

Short integer

Short integer

Short integer

Short integer

HiPot_discharge_multiplier

HiPot_PowerPack_enabled

Short integer

Yes/No

StepHiPot_PowerPack_enabled Yes/No

Description



Length of test.

Ramp rate.

HiPot trip value.



Not used.


Database definition

Table 39. Test results parameters table; Surge test parameters field descriptions.

Field name Type Description surge_test_voltage Short integer Target voltage of test.

surge_no_leads surge_ramp_rate surge_pulses surge_time_scale surge_volts_scale surge_PauseBetweenLeads surge_zero_enabled surge_zero_percent surge_EAR_enabled surge_EAR_percent surge_ppEAR_enabled surge_ppEAR_percent surge_refEAR _percent surge_refwave_test_key surge_PowerPack_enabled

Short integer

Short integer

Short integer

Short integer

Short integer

Yes/No

Yes/No

Short integer

Yes/No

Short integer

Yes/No

Short integer

Short integer

Long integer

Yes/No

Number of leads: 2 or 3.

Ramp rate.

Number of pulses surged at test voltage.

Index indicating the time per division.

0 – 2.5 uS 4 – 50 uS

1 – 5 uS 5 – 100 uS

2 – 10 uS 6 – 200 uS

3 – 25 uS 7 – Auto scaling

Index indicating the volts per division.

0 – 250 w/power pack 1000


2 – 1000 w/power pack 4000

3 – 2000 w/power pack 8000

4 – Auto scale

1=Yes pause; 0=No do not pause.

Zero tolerance error checking on/off.

Zero tolerance percent.

EAR checking on or off.

EAR error tolerance

Pulse to pulse EAR error checking enabled.

Pulse to pulse EAR tolerance percent.

EAR tolerance with reference wave.

0=No reference waveform; if any other number then it is a key to the ref waveform record in the RefSrgWaveform table.

1=PP enabled; 0=No PP


Database definition

Table 40. Test results parameters table; additional fields descriptions.

Field name Type Description surge_AT101_enabled Yes/No 1=AT101 enabled; 0=Not enabled motor_voltage_class temp_RH_enabled

HiPot_rampVTest_enabled

Long integer

Yes/No

Yes/No

Voltage class of the Test ID used

1=Relative Humidity enabled; 0= Not enabled

1=Ramped Voltage Test enabled; 0= Not enabled

Test ID table—(TestId)

The TestId table contains information that is used to set up the test criteria. There is only one motor record per motor. The test_key is the primary key. It is automatically generated when a new test is added. The testid field is a unique 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 test_key Long integer Automatically generated number used as the primary key.

testId datetime_modified

Text (25)

Date/Time temp_enabled resist_enabled

Meg-Ohm_enabled pi_enabled

HiPot_enabled

PrgHiPot_enabled

Surge_enabled

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Test identification.

Date and time stamp as to when a Test ID gets updated.

Temperature test: 1=on; 0=off.

Resistance test: 1= on; 0=off.

Meg-Ohm test: 1=on; 0=off.

PI test: 1=on; 0=off.

HiPot test: 1=on; 0=off.

Step Voltage Test enabled: 1=on; 0=off.

Surge test: 1=on; 0=off.


Database definition

Table 42. Test ID table; temperature test parameters field descriptions.

Field name Type Description temp_isAuto Yes/No 1=Manual; 0=Automatic.

temp_degF_C Yes/No 1=F degrees; 0=C degrees.

Table 43. Test ID table; resistance test parameters field descriptions.

Field name resist_no_leads resist_deltaR_enabled resist_ deltaR_maxpercent resist_external_enabled resist_isAuto resist_4lead_test_enabled

Type

Short integer

Yes/No

Short integer

Yes/No

Yes/No

Yes/No resist_correct_to_temp_enabled Yes/No resist_temp_correct_to Short integer resist_temp_correct_factor Double resist_target_coilRes_enabled Yes/No resist_target_coilRes Double resist_target_coilRes_tolerance Long integer

Description

# of leads (2 or 3) Used also in surge.

1=delta R used in pass/fail; 0=Not used.

Max difference in percent.

Always false 0=No external testing.

1=Automatic; 0=Manual

1=4 lead test enabled; 0=4 lead test disabled

(Only disabled at this time)

Correct resistance 1=Yes; 0=No.

Defines the value that the resistance temperature will be corrected to.

Default 234.5 for copper.

1=Coil resistance checking enabled; 0=not enabled.

Coil resistance to compare tested value with.

Tolerance set for target coil resistance.


Database definition

Table 44. Test ID table; Meg-Ohm test parameters field descriptions.

Field name Type Description

Meg-Ohm_test_voltage Short integer Target voltage of test.

Meg-Ohm_min_Meg-Ohm

Meg-Ohm_test_time

Meg-Ohm_ramp_rate

Short integer

Short integer

Short integer

Meg-Ohm_trip_level Short integer

Meg-Ohm_discharge_multiplier Short integer

Meg-Ohm_PowerPack_enabled Yes/No


Length of test.

Ramp rate.

HiPot trip value.



Table 45. Test ID table; polarization index test parameters field descriptions.

Field name pi_test_voltage pi_min_Meg-Ohm pi_min_ratio pi_ramp_rate pi_trip_level pi_da_only_enabled pi_revert_to_da_enabled pi_discharge_multiplier pi_PowerPack_enabled

Type

Short integer

Short integer

Double

Short integer

Short integer

Yes/No

Yes/No

Short integer

Yes/No

Description



Length of test.

Ramp rate.

HiPot trip value.

1=DA only; anything else PI.



Table 46. Test ID table; HiPot test parameters field descriptions.

Field name

HiPot_test_voltage

HiPot_min_Meg-Ohm

HiPot_test_time

HiPot_ramp_rate

HiPot_trip_level

Type

Short integer

Short integer

Short integer

Short integer

Short integer

Description



Length of test.

Ramp rate.

HiPot trip value.


Database definition

Field name

HiPot_discharge_multiplier

HiPot_PowerPack_enabled

Type

Short integer

Yes/No

Description



Table 47. Test ID table; Surge test parameters field descriptions.

Field name surge_test_voltage surge_no_leads surge_ramp_rate surge_pulses surge_time_scale

Type

Short integer

Short integer

Short integer

Short integer

Short integer surge_volts_scale surge_PauseBetweenLeads surge_zero_enabled surge_zero_percent surge_EAR_enabled surge_EAR_percent surge_ppEAR_enabled surge_ppEAR_percent surge_refEAR _percent surge_refwave_test_key surge_PowerPack_enabled

Short integer

Yes/No

Yes/No

Short integer

Yes/No

Short integer

Yes/No

Short integer

Short integer

Long integer

Yes/No

Description


Number of leads: 2 or 3.

Ramp rate.

Number of pulses surged at test voltage.

Index indicating the time per division.

0 – 2.5 uS 4 – 50 uS

1 – 5 uS 5 – 100 uS

2 – 10 uS 6 – 200 uS

3 – 25 uS 7 – Auto scaling

Index indicating the volts per division.



2 – 1000 w/power pack 4000

3 – 2000 w/power pack 8000

4 – Auto scale

1=Yes pause; 0=No do not pause.

Zero tolerance error checking on/off.

Zero tolerance percent.

EAR checking on or off.

EAR error tolerance

Pulse to pulse EAR error checking enabled.

Pulse to pulse EAR tolerance percent.

EAR tolerance with reference wave.

0=No reference waveform; if any other number then it is a key to the ref waveform record in the RefSrgWaveform table.



Database definition

Table 48. Test ID table; additional fields descriptions.

Field name Type surge_AT101_enabled Yes/No motor_voltage_class temp_RH_enabled

Long integer

Yes/No

HiPot_rampVTest_enabled Yes/No

Description

1=AT101 enabled; 0=Not enabled

Voltage class of the Test ID used

1=Relative Humidity enabled; 0= Not enabled

1=Ramped Voltage Test enabled; 0= Not enabled

Step Voltage test ID table—(TestIdPrgHiPot)

Table 49. Step Voltage Test ID table fields descriptions.

Field name Type test_key Long integer test_voltage min_Meg-Ohm test_time ramp_rate prg_order powerpack_enabled

Long integer

Short integer

Short integer

Short integer

Long integer

Yes/No

Description

Test identification key.

Voltage for this step.

Minimum Meg-Ohm value for this step.

Length of time for this step.

Ramp rate for this step.

Step number.



Database definition

Reference Surge waveform table— (RefSrgWaveForm)

This table contains the waveforms used as test criteria to pass or fail a motor base on a reference waveform.

Table 50. Reference surge waveform table fields descriptions.

Field name refwave_test_key

Type

Long integer

WaveFormatVr

Xscale

Yscale

MicroSecPerPnt

VoltsPerPnt peak_volts1 peak_volts2 peak_volts3 wave1Full wave2Full wave3Full

Double

Integer

Integer

Double

Double

Short integer

Short integer

Short integer

Description

Primary key field it is also stored in

TestParameter and TestId tables. Auto generated number.

Version of waveform record.

Scale index for the x-axis (micro seconds per division).

Scale index for the y-axis (volts per division).

Microseconds per point (Not used at this time).

Volts per point (Not used at this time).

Peak voltage reached for lead 1



Full wave form for lead 1.




Database definition

Database Information table—(DatabaseInfo)

Database information table fields descriptions.

Field name Type Description database_type Text (25) Type of database (AWA, MTA).

revised_date Date/Time database_version software_version revising_app tree_level_1_field_name tree_level_2_field_name

Text (25)

Text (25)

Text (25)

Text (10)

Text (10)

Data and time the database was created or revised.

Version of the database.

Software version that is used with this version of the database.

Application that revised the database.

(AWA, MTA, Data Transfer, and so on).

Motor Location field used for this database, default is Location. The record with the most recent date contains the field description used.

Motor Location field used for this database, default is Building. The record with the most recent date contains the field description used.

Work list table—(Route)

Table 51. Work list table fields descriptions.

Field name route_id motor_key

Type

Text (25)

Long integer route_order Long integer

Description

Name of the route.

Motor key of the motor belonging to this route.

Order of Motor IDs in Route.

Motor voltage class table—(MotorVoltageClasses)

Table 52. Motor voltage class table fields descriptions.

Field name motor_voltage_class class_description

Type

Long integer

Text (64)

Description

Voltage class (480, 4160, and so on).

Voltage class description.


Database definition


Appendix D — Baker AWA-IV specific winding faults

Software fault messages

Failure type Status

PASS

FAIL

FAIL

Tested

FAIL

USER ABORT

EMERGENCY

SHUTOFF

Tested

CANCEL

Failure message

No failure was detected according to the Test

Model given.

A user abort has been detected.

Emergency Shutoff has been detected

No message, cannot determine Pass/Fail because no test criteria was turned on.

User cancelled test.

Resistance failure types

Status

FAIL

Failure type

DELTA R

FAIL

FAIL

CAUTION

OPEN LEADS

TOLERANCE

Reistance out of range

CAUTION

FAIL

FAIL

MAX R Range

Exceeded

No Resistance

Solution

NOISY ADC

Failure message

Resistance test result: Fail – DELTA R. Delta R percent is out of tolerance.

Test results: Fail-OPEN LEADS. Open Leads

Detected.

Test Results: Fail-TOLERANCE Resistance(s) outside of user defined targeted range.

Resistance values must be greater than 0.500 ohms for HIGH VOLTAGE LEADS and greater than 0.001 for the RES LEADS. You may stop

Testing, reconfigure Test ID with the appropriate leads, and repeat the test OR continue with the remaining tests.

Test Results: Caution – MAX Resistance Range

Exceeded.

Possible Open lead(s).

Resistance values do not have a solvable solution.

Instrument detecting excessive electrical noise.

Resistance measurements are unstable. Check for noise sources nearby (welders, VFDs, etc.) or a free wheeling rotor.

DC test failure types

FAIL

FAIL

FAIL

Status

FAIL

FAIL

FAIL

FAIL

Failure type

Over voltage

Open ground

Min Meg-Ohm

Min PI

Over current

No steps defined

Low PRG HPT voltage

Failure message

Over Voltage Condition has been detected.

An open ground has been detected. Check power cord outlet ground for continuity.

Test Result. Fail – MIN MEG-OHM. Meg-Ohm value is less than the minimum tolerance.

PI test results: Fail – Min PI. PI Ratio is less than minimum tolerance.

Test result: FAIL – OVER CURRENT. An over current trip was detected.

No steps for Step-Voltage Test exist in this Test

ID.

The last step voltage is below the previous Meg-

Ohm/PI test voltage.

Surge test failure types

Status

FAIL

FAIL

FAIL

FAIL

FAIL

CAUTION

Failure type

Open leads

Over voltage

Open ground ppEAR Limit

L-L EAR

Unequal zero crossings

Failure message

Test Results: Fail – OPEN LEADS. Open leads detected.

Over Voltage Condition has been detected.

An open ground has been detected. Check power cord power outlet ground for continuity.

Surge test results: Fail – ppEAR LIMIT. Pulseto-Pulse EAR%.

Surge Test Result: Fail – L-L EAR Lead- to-Lead

EAR % is out of tolerance.

Test results: Caution – UNEQUAL ZERO

CROSSINGS Waveforms do not have the same number of zero crossings.


Fault analysis chart

Failure mode

Weak insulation turn-turn

Weak insulation phase-phase

Weak insulation coil-coil

Turn-turn shorts

Phase-phase shorts

Coil-coil shorts

Open coils

Reversed coils

Unbalanced phases

Weak ground wall insulation

Dirty windings

Moisture

Faulty feeder cables

Motor Lean line connections

Winding resistance

MegOhm test

X

X

X

X

X

X

X

X

X

X

PI test

X

X

X

X

Step

Voltage

Surge

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

AWA-IV static testing parameters, indicators, and common causes

Parameter

Resistance

Insulation resistance



Surge test

Surge test

Indication

Imbalance

Low MegOhms

Overcurrent trip

HiPot Non-linear current

Erratic wave

Wave imbalance

Result/Cause

Indication of high resistance connection.

Improper winding connection, or circuit shorting.

Indication of significant thermal degradation, contamination of moisture influences.

Insulation breakdown at the test voltage.

Indication of imminent or existing insulation failure.

Indicates insulation is reaching its end of life, or contamination near exposed conductors.

Indicates weakness in copper-to-copper insulation. Most likely turn-to-turn insulation.

Indicates insulation’s end of useful life.

Indicates winding imbalances caused by asymmetries from the winding process or an insulation failure.



Index

Symbols

#1 Test ID armature 110

#2 Test ID field 110

A

Adding a new motor 46

Adding a route 39

Applicable standards 159

Applications: What to do first 148

Archiving a database 19

Armature preparation 135

Armature testing 136

AWA-IV static testing parameters, 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 tester specifications 157

Baker AWA-IV 6 kV/12 kV model front panel 24

Baker AWA-IV 6 kV model distinctions 25

Baker AWA-IV instrument overview 23

Baker AWA-IV software overview 27

Baker AWA-IV specific winding faults 183

Baker ZTX E-stop and remote E-stop 7

Index

Balance resistance test or line-to-line resistance

78

Bar-to-bar armature testing 136

C

Capturing screens 35

Checking test leads for broken sections 152

Cleaning and decontamination 8

Coil resistances 59

Combining Baker AWA-IV host and power pack tests 119

Common application problems 148

Conducting DC tests with the Baker PP24 singlephase test lead power pack 130

Conducting DC tests with the Baker PP30 threephase test lead power pack 125

Conducting Surge tests with the Baker PP24 single-phase test lead power pack 131

Conducting Surge tests with the Baker PP30 three-phase test lead power pack 127

Configure Surge test 89

Configuring a printer 26

Configuring a Surge test for armature bar-to-bar testing 136

Configuring 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 85

Connecting Baker AWA-IV to the Baker ZTX accessory 134

Connecting test leads to motor under test 26

Consequences of not organizing data 11

Creating a motor ID 81

Creating a new database 12, 28

Creating a new motor voltage class 103

Creating a Surge test reference 66

Creating a test ID 83

Creating IDs and setting up the test 119

D

DA/PI test 78

Database definition 161

Database Information table—(DatabaseInfo) 181

Database management 11

Database management and maintenance 11

Database menu 34

Data tab—Application view 47

Data tab—Nameplate view 45

Data tab—PI view 52

Data tab—Results Summary view 49

Data tab—Step/Ramp-Voltage view 53

Data tab—Surge view 50

Data Transfer feature 15

DC motor/generators 116

DC test failure types 184

DC Tests setup window 60

Deleting an existing motor from the database 46


Index

Deleting a route 40

Delta wound resistance measurement 59

E

E bar graph 65

Editing motor IDs on an existing route 40

Emergency power shut-off 24, 26

Emergency stop button 6

Entering resistance measurements 59

Environmental conditions 9

Explore tab 37

F

Fault analysis chart 185

Field coils 108

File menu 32

Fine tuning the technique 111 footswitch 26 formatting 1

G

General operation, maintenance, and service information 8

Generating CSV files 145

H

Help menu 35

High-voltage 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

I

HiPot test 79 information devices 1

Insulation Resistance/Meg-Ohm 73

L

Lifting the instrument 9

Limited output surge waveform 151

M

Main menu 32

Main window 31

Making basic connections and starting the analyzer 25

Manually entering resistance measurements 59

Max Delta R% Resistance 72

Meg-Ohm test 78

Memo table—(Memo) 166

Motor ID field 44

Motor ID tab 38

Motor location fields 44

Motor troubleshooting 108

Motor voltage class 103

Motor voltage class table—(MotorVoltageClasses)

181

N

Nameplate table—(MotorID) 161

O

Open circuit test to verify tester operation 152

Open condition display 150

Open ground check 151


Index

Opening an existing database 13, 29

Operating and shipping positions 10

Operating position 118

Overcurrent trip test 152

P

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

Q

Quality control 108

R

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

S

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


Index

Step Voltage test ID table—(TestIdPrgHiPot) 179

Step Voltage test results table—

(TestResultsPrgHiPot) 169

Surge test 79

Surge test failure types 184

Surge test reference 66

Surge test results 70

Surge test results table—(SurgeWaveform) 170

Surge test setup window 63

Symbols on equipment 3

T

Tabs 37

Technical assistance / authorized service centers

8


155

Temperature/Resistance test setup window 56

Test configuration 56

Test ID table—(TestId) 175

Testing a production motor by comparing with a reference motor 69

Testing a reference motor 67

Testing with the Baker PP24 single-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

Test results table—(TestResults) 162

Third-party software warning 153

Toolbar 36

Tools menu 35

Transferring motor and test results data 15

Transferring test IDs 18

U

Unpacking the unit 8

Updating an existing motor’s nameplate information 46

Using multiple databases 14

Using power packs with 6/12 kV models 117

Using the Baker ZTX with Baker AWA-IV analyzers 133

Using the footswitch 26

Using the Hi L technique to test DC shunt or compound motor insulation, evaluate shunt fields, and test interpoles 110

Using the Tests tab 55

Using the Trending tab 71

Using version 4 software for the first time 30

V

Version 4.0 database definition 161

Viewing Surge test results 70

Viewing test data 42

View menu 33


Index

W

Warranty return 154

Warranty return form 154

Window menu 34

Work list table—(Route) 181

Wye wound resistance measurement 59


Seals

Bearings and units

Mechatronics

Lubrication

Services systems

The Power of Knowledge Engineering

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© SKF USA, Inc. 2017

The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior written permission is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of the use of the information contained herein.

71-015 EN V13.2 Static Motor Analyzer—Baker AWA-IV User Manual · February 2018 skf.com

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