Baker Instrument Company D12R User manual

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D12R, D6R, D3R Users Manual
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Users Manual
Digital Winding Tester
D12R, D6R, 3R
Baker Instrument Company, an SKF Group Company,
4812 McMurry Ave. Suite 100
Fort Collins, CO 80525
[phone]
[phone] (FAX)
800-752-8272 (USA Only)
Note: 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, may 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 does radiate radio frequency energy while in the active test mode. Care should be taken
to insure this radio frequency energy causes no harm to individuals or other nearby equipment.
Information furnished in this manual by Baker Instrument Company, an SKF Group Company,, is
believed to be accurate and reliable. However, Baker Instrument Company, an SKF Group
Company, 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 Baker Instrument Company, an SKF Group
Company.
Warning:
Baker Instrument Company, an SKF Group Company, 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 Baker Instrument Company, an SKF Group Company, Fort Collins,
Colorado.
Intended use of instrument
The D12R, D6R and D3R, is offered by Baker Instrument Company, an SKF Group Company’s
standard products division. This machine is intended to be used for the detection of weak
insulation within electric motors by trained professionals. It is intended to perform only the
specified tests that this manual explains in detail. Please refer to chapters in this manual
concerning specific operation of instrument.

Intro and warranties
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Warranties; Disclaimers
Limited Warranty as to Baker/SKF Brand Products.
a) Baker/SKF warrants that Baker/SKF brand Products, if any, that are sold under the
Agreement shall be of the kind and quality described in Baker/SKF's acknowledgment of
Buyer's Order, and shall be free of material defects in workmanship and material for a
period from the date of shipment equal to (i) twelve (12) months in the case of new
Products (including factory-installed circuit boards, accessories and options purchased
concurrently with the applicable Product), (ii) six (6) months in the case of used or
refurbished Products, and new circuit boards, accessories and options delivered separately
from the applicable Product, (iii) a period of ninety (90) days from the date of shipment in
the case of used or refurbished circuit boards. If any such Product , accessory or option
is not as warranted, Buyer must notify Baker/SKF thereof in writing within the applicable
warranty period.
b) Baker/SKF's sole obligation, and Buyer's sole remedy, under the foregoing warranty shall
be to provide the parts and labor for the repair or replacement (at Baker/SKF's sole
option) of defective parts, recalibration of any portions of a product that could reasonably
have been affected by the repair, and functional verification to affirm proper operation.
When, subject to the next sentence, the Buyer returns Products, accessories or options
to the Baker/SKF factory for warranty service, Baker/SKF will bear the cost of return
packaging, and shipping , and insurance ,on the return shipment. For Products,
accessories or options that Baker/SKF designates as “on-site service only” due to their
size, the permanence of their installation pr otherwise, travel expenses (including labor
costs for time spent traveling) for warranty services are covered to the location of
original shipment and installation. Products, accessories and options that are capable of
being returned to the factory for service may receive warranty service on site, but all
travel expenses (including labor charges for time spent traveling) shall be the
responsibility of Buyer.
c) For warranty coverage of “on-site service only” items, Buyer must make available to
Baker/SKF a knowledgeable operator to assist with preliminary diagnosis prior to a
service trip being scheduled. Buyer, in connection with a request for on-site service,
must be capable of authorizing charges for the service visit in the event the issues
discovered are not covered by warranty, such as application errors or installation errors.
If Buyer, having elected to perform installations without Baker/SKF’s participation and
having encountered irresolvable problems, shall be charged for an installation if on-site
assistance is necessary, except when defective product is determined to be the cause.
Trademarks
All other trademarks, service marks or registered trademarks appearing in this manual are
the trademarks, service marks or registered trademarks of their respective owners.

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Users Manual ...........................................................................................................................................1
Intended use of instrument ................................................................................................................... 1
Warranties; Disclaimers.......................................................................................................................... 2
Limited Warranty as to Baker/SKF Brand Products. .................................................................... 2
Trademarks .............................................................................................................................................. 2
Preface...............................................................................................................................................................7
Important safety information..................................................................................................................... 7
General Safety Precautions ...................................................................................................................7
Safety term definition ............................................................................................................................. 7
Other Important Safety warnings .........................................................................................................7
Symbols on equipment...........................................................................................................................8
Other Information ........................................................................................................................................ 8
Cleaning & decontamination..................................................................................................................8
Technical assistance / Authorized Service Centers ............................................................................ 9
Accessory interconnection and use....................................................................................................... 9
Intermittent operation limits.................................................................................................................. 9
Installation requirements .......................................................................................................................9
Unpacking the unit .................................................................................................................................. 9
Pollution Degree II...................................................................................................................................9
Power requirements ............................................................................................................................... 9
Environmental conditions....................................................................................................................... 9
Declaration of Conformity.........................................................................................................................10
1........................................................................................................................................................................11
Instrument Overview .....................................................................................................................................11
Front panel controls ..................................................................................................................................11
Test lead connections .......................................................................................................................13
On-line labels .........................................................................................................................................14
Safety precautions for setup................................................................................................................14
Initial tester power-up and checkout .................................................................................................15
Using the footswitch..............................................................................................................................15
2........................................................................................................................................................................17
Test sequence, voltages & applicable standards.......................................................................................17
Recommended testing sequence.............................................................................................................17
1. Coil Resistance test...........................................................................................................................17
2. Megohm test......................................................................................................................................17
3. Principles of the Dielectric Absorption (DA) test ..........................................................................17
4. Principles of the Polarization Index (PI) test.................................................................................17
5. DC HiPot test.....................................................................................................................................18
6. Surge test...........................................................................................................................................18
Recommended test voltages – HiPot and Surge tests ....................................................................18
Applicable Standards.............................................................................................................................20
3........................................................................................................................................................................21
Coil Resistance testing...................................................................................................................................21
Principles of Coil Resistance testing........................................................................................................21
Other Important Safety warnings .......................................................................................................21
Resistance Test Display ........................................................................................................................22
Resistance test checklist.......................................................................................................................22
Auto ranging Resistance measurement algorithm...........................................................................23
Saving & recalling measurements ......................................................................................................24
Indications of problems in a motor.....................................................................................................24
4........................................................................................................................................................................25
Principles and theory of DC testing.............................................................................................................25
Principles of DC testing.............................................................................................................................25
5........................................................................................................................................................................29
Performing high voltage DC tests................................................................................................................29
Other Important Safety warnings .......................................................................................................29
The test display ..........................................................................................................................................30

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High voltage DC test checklist .............................................................................................................31
DC testing ...............................................................................................................................................31
Full DC testing of a motor....................................................................................................................31
Performing only a Megohm test.....................................................................................................33
Performing only DC over voltage test (DC HiPot test).....................................................................33
Sample data showing good & poor insulation ..................................................................................34
Storing the test results in memory ....................................................................................................34
Using the footswitch..............................................................................................................................34
The HiPot over current trip indicator.................................................................................................35
Effects of temperature..........................................................................................................................35
Step Voltage test ...................................................................................................................................35
Step Voltage test procedure ................................................................................................................35
7........................................................................................................................................................................37
Performing Surge tests.................................................................................................................................37
Surge test display ......................................................................................................................................37
Other Important Safety warnings .......................................................................................................37
Surge test setup ....................................................................................................................................38
480V three phase motor check list.....................................................................................................39
Single coil surge test and set-up ........................................................................................................40
Example: Comparison to a master coil ..........................................................................................42
8........................................................................................................................................................................43
Surge test applications..................................................................................................................................43
Maintenance testing ..................................................................................................................................43
Application Notes...................................................................................................................................44
Single phase motors and two terminal devices................................................................................44
Determination of a fault...................................................................................................................44
Form coils ...............................................................................................................................................45
Determination of a fault...................................................................................................................45
Notes and tips for form coils...........................................................................................................45
Three phase motors..............................................................................................................................46
Determination of a fault...................................................................................................................46
Two or more single coils ......................................................................................................................46
Determination of a fault...................................................................................................................47
Notes and precautions for two single coils ...................................................................................47
Wound rotor motors .............................................................................................................................47
Determination of a fault...................................................................................................................48
Synchronous motor/generator............................................................................................................48
Determination of a fault...................................................................................................................48
Pole piece fault ......................................................................................................................................48
Stator winding fault ..............................................................................................................................48
Chiller motor testing .............................................................................................................................49
Field coils ................................................................................................................................................49
DC motor/generators............................................................................................................................49
Armatures...............................................................................................................................................49
Bar-to-Bar Surge test .....................................................................................................................49
Span testing .......................................................................................................................................49
Determination of a fault...................................................................................................................50
Testing large AC stators/motors .........................................................................................................52
Notes and tips for large AC stator/motors....................................................................................52
Rotor loading (coupling) when testing assembled motors..............................................................52
Testing assembled motors from the switchgear ..............................................................................54
Transformers .........................................................................................................................................54
Single phase transformers ..............................................................................................................55
Three phase transformers...............................................................................................................55
Determination of a fault...................................................................................................................55
9........................................................................................................................................................................57
Documenting tests.........................................................................................................................................57

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Store........................................................................................................................................................57
Store Resistance data...........................................................................................................................58
Store HiPot and PI data .......................................................................................................................58
Store Surge data ...................................................................................................................................58
Recall .......................................................................................................................................................59
Recall Resistance data ..........................................................................................................................60
Recall HiPot data ...................................................................................................................................60
Recall Surge data ..................................................................................................................................60
Print.........................................................................................................................................................61
Clear ........................................................................................................................................................61
Erase........................................................................................................................................................61
Compatible printer information...........................................................................................................62
Version 3 firmware ...............................................................................................................................62
Supplement 1 .................................................................................................................................................63
PP130/PP230 power pack...........................................................................................................................63
Important safety information...................................................................................................................63
Other Important Safety warnings .......................................................................................................64
Instrument notices ................................................................................................................................64
Emergency Shut-Off Button................................................................................................................65
Initial set-up ...........................................................................................................................................65
Power pack resistance testing.............................................................................................................66
Three-phase test lead ..........................................................................................................................66
Output configuration .............................................................................................................................66
Operating and shipping position..........................................................................................................66
Power pack operation ...............................................................................................................................67
Surge testing..........................................................................................................................................67
DC HiPot testing ....................................................................................................................................68
Lead connection.....................................................................................................................................69
Single phase lead connections.............................................................................................................69
Note regarding 220/240 VAC units....................................................................................................69
Lifting the instrument...........................................................................................................................70
Supplement 2 .................................................................................................................................................71
PP185 power pack ........................................................................................................................................71
Important safety information...............................................................................................................71
Other Important Safety warnings .......................................................................................................72
Instrument notices ................................................................................................................................72
Emergency Shut-Off Button................................................................................................................73
Initial set-up ...........................................................................................................................................73
Power pack resistance testing.............................................................................................................74
Three-phase test lead ..........................................................................................................................74
Output configuration .............................................................................................................................74
Operating and shipping position..........................................................................................................74
Surge testing..........................................................................................................................................75
DC HiPot Testing........................................................................................................................................76
Sample data showing good & poor insulation ..................................................................................77
Storing the test results in memory ....................................................................................................78
Using the footswitch..............................................................................................................................78
The HiPot overcurrent trip indicator ..................................................................................................78
Effects of temperature..........................................................................................................................78
Armature Testing ..................................................................................................................................79
Bar-to-bar testing/armature testing..................................................................................................79
Bar-to-bar testing with the PP85......................................................................................................80
Determination of a bar-to-bar fault ..............................................................................................80
Armature application recommendations............................................................................................81
Three phase lead connection...............................................................................................................81
220/240 V AC Units..............................................................................................................................81
Lifting the instrument...........................................................................................................................82

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Supplement 3 .................................................................................................................................................83
PP40 power pack...........................................................................................................................................83
Important safety information...............................................................................................................83
Other Important Safety warnings .......................................................................................................84
Emergency Shut-Off Button................................................................................................................85
Initial set-up ...........................................................................................................................................85
Output configuration .............................................................................................................................85
Power pack operation ...............................................................................................................................86
Surge testing..........................................................................................................................................86
DC HiPot testing ....................................................................................................................................87
Note regarding 220/240 VAC units....................................................................................................88
Output configuration .............................................................................................................................88
Operating and shipping position..........................................................................................................88
Lifting the instrument...........................................................................................................................89
Supplement 4 .................................................................................................................................................91
AT101D Bar-to-bar armature testing .......................................................................................................91
Other Important Safety warnings .......................................................................................................91
Operation ................................................................................................................................................93
Determination of a fault .......................................................................................................................94
Application recommendations..................................................................................................................95
Specifications for the AT101D Bar-to-bar armataure testing accessory ....................................95
Appendix A Winding Faults...........................................................................................................................97
Appendix B Troubleshooting ........................................................................................................................99
Self help and diagnostics..........................................................................................................................99
Step #1: Basic information ................................................................................................................99
Step #2: Applications or service problem?......................................................................................99
Applications: What to do first! ................................................................................................................99
Other Important Safety warnings .................................................................................................... 100
Common application problems......................................................................................................... 101
Service: What to do first? ................................................................................................................ 102
Open condition display....................................................................................................................... 102
HiPot display checks........................................................................................................................... 103
HiPot over current trip check ........................................................................................................... 103
Open ground check ............................................................................................................................ 104
Limited output surge waveform....................................................................................................... 104
Warranty return...................................................................................................................................... 104
Appendix C Technical specifications and calibration.............................................................................. 107
Technical specifications...................................................................................................................... 107
Accuracy of measurements - Coil Resistance test........................................................................ 108
Testing Accuracy - HiPot Measurements....................................................................................... 108
Voltage measurement accuracy – Surge (D12R) .......................................................................... 108
Voltage measurement accuracy – Surge (D6R/D3R) ................................................................... 108
Calibration information...................................................................................................................... 108
Index.............................................................................................................................................................. 109

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Preface
Important safety information
General Safety Precautions
Note: The general safety information presented here will be for both operating and service
personnel. Specific warnings and cautions will be found throughout this manual where they
apply.
Note: If the equipment is used in any manner not specified by Baker Instrument Company,
an SKF Group Company, the protection provided by the equipment may be impaired.
Safety term definition
DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING: Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION: Indicates a hazardous situation, which, if not avoided, could result in minor or
moderate injury.
NOTICE: “NOTICE” is the preferred signal word to address practices not related to personal
injury.
Other Important Safety warnings
Failure to follow these precautions could result in severe electrical shock or death.
1) Never attempt a two-party operation. Always know what test is being performed
and when. FOR EXAMPLE: DO NOT adjust test leads when footswitch is being
operated. Leads will have live voltage and severe electric shock may result.
2) For capacitor-started motors or systems with surge arrestors/power factor
capacitors, be sure to disconnect all capacitors from the test circuit before testing.
Danger
High Voltage
To prevent serious injury or death:
-Do not use in explosive atmospheres.
-Do not contact test leads or device being testing
while test is in progress or during discharge period.
-Do not connect test leads to live circuits.
Read and follow safety precautions and safe operating
practices in operator manual. Do not exceed maximum
operating capabilities of this instrument.

Safety equipment warnings and CE compliance statements
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3) Upon completion of a DC High Potential, Megohm, Polarization Index, Step Voltage,
Dielectric absorption, or Continuous Ramp test, before disconnecting the test leads,
short the winding, motor, etc., to ground and allow time for discharge. If this is not
done, voltage may still be active on leads and tested components.
4) Make sure the tester leads are disconnected before the motor is energized or
powered up.
5) Do not remove the product covers or panels or operate the tester without the
covers and panels properly installed. Components on inside of tester carry voltage
for operation and if touched can render a shock.
6) Use appropriate safety equipment required by your organization, including high
voltage globes and eye protection.
7) Repair Parts Warning : Defective, damaged, or broken test leads must be
replaced with factory-authorized parts to ensure safe operation and maintain
performance specifications.
8) Ground the product : This product is grounded through the grounding conductor
of the power cord. To avoid electrical shock, plug the power cord into a properly
wired/grounded receptacle before connecting the product test leads.
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!
9) This instrument is NOT waterproof or sealed against water entry.
10) The unit is for indoor use. If used outdoors, the unit must be protected from rain,
snow and other contaminants.
Symbols on equipment
Protective conductor terminal. Located beside black ground test lead
on front panel of instrument.
Earth (ground) terminal
Frame or chassis terminal. Located on rear panel of instrument by
ground terminal.
Warning about hazardous voltage and risk of severe electrical shock or
death. Located beside each red test lead on front panel of instrument.
Other Information
Cleaning & decontamination
The D3R/D6R/D12R should be kept 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

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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.
Accessory interconnection and use
The D3R/D6R/D12R are equipped with a footswitch standard. Other accessories, such as the
AT101ZTX and safety lights are optional. Please see details about these accessories in later
chapters in this manual.
Intermittent operation limits
At this time there are no intermittent operation limits to the use of the AWA unit.
Installation requirements
The unit may be operated
1) Flat on the bottom of the unit,
2) Flat on the back of the unit, or
3) Held at an angle using the rotating handle.
There are no ventilation requirements.
The unit is intended for use in Installation Category II (Portable Equipment) areas and
pollution Degree II Environments where occasional non-conducting condensing pollution can
be encountered.
Unpacking the unit
Carefully remove the following items from the shipping boxes.
D3R, D6R or D12R
Power cord
Operation manual
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 100-240VAC, 50-60 Hz, 2 amps AC maximum current draw.
The unit is fused using 2.5A fast blow fuses. Replace fuses with like type and rating.
Environmental conditions
1) The unit has been tested for use up to 2000 m.
2) The tester should only be operated in temperatures ranging from 41 to 104
degrees Fahrenheit (5° C to 40° C).
3) This unit is for use at a maximum relative humidity of 80% for temperatures up to
31 °C decreasing linearly to 50% relative humidity at 40°C. This unit is intended for
Installation Category II in a Pollution Degree II environment.

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Declaration of Conformity
Manufacturer’s Name & Address:
Baker Electrical Instrument Company, an SKF Group Company,
4812 McMurry Ave
Fort Collins, CO 80525
USA
Equipment Description: Testers for Surge, DC Hi-Pot, and Winding Resistance of motors.
Equipment Model Designations: D3R, D6R, D12R.
Application of Council Directive 72/23/EC 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/EC and Council Directive 2004/108/EC on the
approximation of the laws related to Member States relating to the electromagnetic
compatibility, as amended by: Council Directive 93/68/EC. Note: due 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: John S. Wilson
Title: Manager, Standard Products.