Baker Instrument Company PP24 User manual

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User’s Manual
DC HiPot/Surge Tester (Power Pack)
Model PP24
Baker Instrument Company, an SKF Group Company
4812 McMurry Avenue
Fort Collins, CO 80525
[phone]
[phone] FAX
[phone] USA Only

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Warranties; Disclaimers
Limited Warranty as to Baker/SKF Brand Products.
1) 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.
2) 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.
3) 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.
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.

Table of Contents
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Warranties; Disclaimers..............................................................................................................2
Limited Warranty as to Baker/SKF Brand Products. .................................................................... 2
1 ........................................................................................................................... 5
Preface.................................................................................................................. 5
IMPORTANT SAFETY INFORMATION.......................................................................................................5
General Safety Precautions ........................................................................................................ 5
Safety term definition ................................................................................................................. 5
Other Important Safety warnings ..............................................................................................5
Power Source Precautions .........................................................................................................6
Ground the product.....................................................................................................................6
Operation notes ...........................................................................................................................6
Symbols on equipment ............................................................................................................... 7
OTHER INFORMATION..........................................................................................................................7
Cleaning & decontamination....................................................................................................... 7
Technical assistance / Authorized Service Centers...................................................................7
Intermittent operation limits.......................................................................................................7
Installation requirements............................................................................................................7
Unpacking the unit ......................................................................................................................7
Power and utility .........................................................................................................................8
Environmental.............................................................................................................................. 8
Storage (indoor/outdoor) ............................................................................................................8
Shipment......................................................................................................................................8
1 ......................................................................................................................... 11
Getting started ................................................................................................... 11
GENERAL INFORMATION ................................................................................................................... 11
How Does the PP24 Work?......................................................................................................11
Recommended Test Voltages ...................................................................................................12
2 ......................................................................................................................... 13
DC testing/DR unit............................................................................................... 13
Other Important Safety warnings ............................................................................................13
DR DC Tests Operation.............................................................................................................14
Megohm/PI/HiPot testing..........................................................................................................15
3 ......................................................................................................................... 21
Surge testing/DR Unit......................................................................................... 21
Other Important Safety warnings ............................................................................................21
SURGE............................................................................................................................................. 22
Printing a Report.......................................................................................................................26
EAR .............................................................................................................................................26
4 ......................................................................................................................... 29
Testing with a AWA unit ..................................................................................... 29
Other Important Safety warnings ............................................................................................29
DC TESTING WITH AN AWA............................................................................................................. 30
Megohm/PI/Hipot Testing .........................................................................................................31

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5 ......................................................................................................................... 33
Surge Testing/AWA.............................................................................................. 33
Other Important Safety warnings ............................................................................................33
SURGE TESTING WITH THE AWA AND PP24................................................................................... 34
Performing Complete Motors Tests with the AWA.................................................................36
Index................................................................................................................... 37

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1
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.

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3) Upon completion of a DC High Potential, Megohm, Polarization Index, Dielectric
absorption, 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.
a. 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.
Power Source Precautions
This product is intended to operate from a power source that does not apply more than
nominal 120 volts RMS (ST103/ST106/ST112) or nominal 240 RMS (ST203/ST206/ST212)
between the supply conductor or between either supply conductor and ground. A protective
ground connection by way of the grounding conductor in the power cord is essential for safe
operation.
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 receptacle before connecting the
product test leads.
Operation notes
−Irregularities, particularly vertical peaks, may be seen in the first cycle of the wave
pattern. These occur most frequently on large, high voltage motors. Do not interpret
these as faults in the winding. Any winding fault will be seen through the entire wave
pattern.
−Do not change the Test Lead Select, if so equipped, switch setting during a test.
−When increasing the applied voltage, switch to a higher Volts/Div setting so the entire
wave pattern remains visible on the display.

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−Always return the Output Voltage control to Min when a test is complete. Begin each
test at the Min voltage setting. Failure to do so may result in damage to the test winding
and/or the tester.
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 ST103A, ST106A, or ST112A 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 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.
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.
ST103A, ST106A or ST112A
Power cord

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Users Manual
Power and utility
Input power must be 110 to 120 VAC at 60 Hz for the ST103/ST106/ST112A (220 to 230
VAC at 50 Hz (single phase source only) for the ST203/ST206/ST212). Please be aware that
fluctuations in input voltage will affect output voltages and calibration.
Environmental
The tester should only be operated in temperatures ranging from 0 to 100 degrees
Fahrenheit (-17.8 to 37.8 degrees Celsius).
As with all insulation dielectric and resistivity measurements, humidity will affect the condition
of the instruments components over time. Relative humidity of the storage environment
should be less than 50 percent.
Storage (indoor/outdoor)
This instrument should not be stored in any location where water entry to the instrument
could occur. Also, humidity will affect the operation of the instrument.
Shipment
All Baker testers are shipped using factory foam-filled containers. Should the tester be
returned to Baker Instrument Company, an SKF Group Company for any reason, we
recommend using the original packaging the unit came in or the following factory specified
packaging:
Contact Baker Instrument Company, an SKF Group Company to order factory-specified
packaging for your testers.
Foot Switch
The PP24 comes with a foot switch that plugs into the front panel of the instrument. This foot
switch takes the place of the Test button on the unit’s front panel. Often, it is convenient to
use the foot switch especially when making PI measurements.
Safety Lights
For those customers who use testing safety lights in their operations, a set of safety lights and
a remote test inhibit switch are provided with the instrument. These lights also plug into the
front panel near the foot switch.
There are two plastic boxes – the Light box houses a (flashing) red light and a green light, the
E-Stop box contains an E-Stop button as well as red & green indicator lights. These two
boxes can be used together or separately, For example, the E-Stop box can be used by itself.
The cables connecting the two boxes are interchangeable and the Light box can be connected
to the cables from either end.

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CE Declaration of Conformity
Manufacturer’s Name & Address:
Baker Electrical Instrument Company, an SKF Group Company
4812 McMurry Ave
Fort Collins, CO 80525
USA
EC Representative’s Name & Address:
Baker Instrument GmbH
Hutbergstrasse 21
D-90475 Nurnberg
Germany
Equipment Description: Testers for Surge, DC Hi-Pot, and Winding Resistance of
motors.
Equipment Model Designations: PP124 and PP224.
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: Mike Teska
Title: Engineering Manager.

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1
Getting started
General Information
The PP24 is a booster pack for a Baker Instrument Company, an SKF Group Company host
surge tester that allows large high voltage motors, windings, and coils to be tested for
insulation integrity. The PP24 is ideal for testing large 4kV and 7kV class windings.
The PP24 cannot operate alone - a Baker AWA or DR host tester is required to operate the
PP24. The host has the brains to control the PP24 and can save the test data taken with the
PP24.
How Does the PP24 Work?
The host unit is placed on top of the PP24 and the two units are connected with an interface
cable. Once the two machines are powered and operating, the host unit is configured to talk
IEEE 522 IEC 34-15
Surge Test (for
HV form wound
only)
EASA
Chapter 13
New In
Service 1.2 x 50 0.2us In Service
Vline 3.5*pu 75% of
new 4E+5000 65% 2E+1000
480 1372 1029 6920 4498 1960
575 1643 1232 7300 4745 2150
600 1715 1286 7400 4810 2200
2300 6573 4930 14200 9230 5600
4160 11888 8916 21640 14066 9320
6900 19718 14789 32600 21190 14800
13800 39437 29578 60200 39130 28600
Fig 1-1: PP24 Front Panel 1

Applicable Voltages and Standards
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to the PP24. This configuration depends on which unit, AWA or DR, is being used and is
described in the chapters below.
A test is started with the PP24 by manipulating the controls on the PP24 only. No testing
controls on the host unit are used during a PP24 test. The test leads for the host unit should
be coiled up and placed on top of the host so that the host and PP24 test leads are separated
and not confused with each other.
The output voltage of the PP24 is manually controlled by the operator. Since the operator is
in full control of the PP24, care should be taken to ensure the testing environment is safe, the
test leads won’t accidentally shock a person (including the operator), and the test voltage is
not exceeded for the motor being tested.
During the test, the host unit records and display’s the PP24’s readings. Once a test is
finished, the PP24’s readings are saved in the host’s memory.
Recommended Test Voltages
There are several organizations that establish a test voltage for testing a motor winding: IEEE,
EASA, IEC, and NEMA. The table below shows surge testing voltages.
The easiest formula to remember is 2V+1000 which lands nicely in the middle of the IEEE
recommended voltages. The European IEC voltages are much higher than the test voltages
most often used in the US.
The HiPot test voltages are shown in the table below:
HiPot Test Voltages IEEE 95-1977 (Para 5.2 for maintenance proof testing)
EASA DC
HiPot
(Chapter 8)
IEEE 95 Min
V IEEE 95 Max V New IEEE 95 Min V
Vline Vline*1.25x1.7 Vline*1.5*1.7 3.4*Vline+1700 Vline Vline*1.25x1.7
480 1020 1224 3332 480 1020
575 1222 1466 3655 575 1222
600 1275 1530 3740 600 1275
2300 4888 5865 9520 2300 4888
4160 8840 10608 15844 4160 8840
6900 14663 17595 25160 6900 14663
13800 29325 35190 48620 13800 29325
NEMA MG-1-1987
DC HiPot
New
Acceptance
NEMA MG-1-1987 DC
HiPot
New
Acceptance
Vline MG-1-20.48.2 MG-1 3.01.12 MG-1-20.48.2
(2E+1000)*1.7 75% of new (2E+1000)*1.7
480 3332 2499 3332
575 3655 2741 3655
600 3740 2805 3740
2300 9520 7140 9520
4160 15844 11883 15844
6900 25160 18870 25160
13800 48620 36465 48620
Again, the 2V+1000 formula gives a HiPot test voltage that nicely fits within many of the
industry practiced test voltages.

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2
DC testing/DR unit
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.
3) Upon completion of a DC High Potential, Megohm, Polarization Index, Dielectric
absorption, 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
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.

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a. 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.
DR DC Tests Operation
This chapter describes how to connect and operate a Baker Digital tester, abbreviated DR,
with the PP24. The DR tester must be calibrated to the specific PP24 being used. The
calibration stickers on both instruments will have the serial number of the instrument it is
calibrated to.
Place the DR unit on top of the PP24 and connect the interface cable to the two units. Coil up
the DR’s test leads and place them on top of the DR.
Connect AC power to both units. The DR can be powered from the short AC power cord from
the PP24. The PP24 is set up for either 120VAC or 240VAC (50 or 60Hz), but not both
voltages. The DR can use either 120 or 240VAC.
1) Turn on both the PP24 and DR.
2) The DR will go through a memory test. When the memory test is finished,
3) Press the Clear button to initialize the DR’s display.
4) Move the Function knob on the DR to the AUX position as shown in Fig 2-2.
Fig 2-1: Digital main screen

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5) Move the Function knob on the PP24 to the test desired – either the Surge position
for surge testing or 100uA/div for HiPot testing as shown in Fig 2-3.
6) Connect the winding to be tested. Ensure safety.
7) Press and hold the Test button on the PP24 to start the test. The red Testing
lamp will illuminate showing a test is active.
8) Increase the test voltage using the PP24’s output control knob. If the control knob
was at a position other than zero when the Test button was pressed, the unit will
not enable until the knob is turned down to zero output.
9) Observe on the screen, record and save the test results to the tester.
Megohm/PI/HiPot testing
Before going into the DC tests with the PP24, it must be noted that the PP24 may require a
voltage regulator to stabilize the incoming power to the unit. If the incoming AC is not well
regulated, the output voltage of the PP24 will change along with any changes in the incoming
AC power. Varying AC power will cause the leakage current to vary to a degree that the
Megohm, PI and HiPot tests may not be accurate. If poor incoming power conditions prohibit
accurate readings, a power conditioner should be used to filter the incoming power to the
Fig 2-2: Function knob
Fig 2-3: Function switch

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PP24. Also, very accurate Megohm and PI measurements can be made with the DR which
has a very tightly regulated high voltage power supply regardless of the quality of the
incoming power.
To perform Megohm/PI/HiPot testing with the PP24, ensure the two units are connected &
powered as described above, follow these instructions:
1) Connect the single red test lead to the winding to be tested and at least one black
lead to the motor frame. A good practice is to connect all three black leads to the
motor frame.
2) Set the Function knob on the PP24 to 100uA/div
Fig 2-5: Function switch at 100 µA/Div
3) After insuring the testing environment is safe, press and hold the Test button.
4) Smoothly turn the output control knob up to the required test voltage. The output
voltage and leakage current will be displayed on the screen of the DR host. Do not
Fig 2-4: Single lead connection

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turn the output control knob so fast that the PP24 HiPot trips while charging the
motor’s ground wall capacitance.
5) Once the test voltage is reached, stop turning up the output control knob, set the
time to zero by pressing the T=0 button on the DR, and follow the instructions on
the DR’s display on changing the current range to the most sensitive range. The
test button must still be depressed for the entire test. Releasing the test button will
cause testing to stop.
6) As key times are reached during the test, values will appear on the screen. Once 60
seconds has passed per IEEE 43, press the Save Meg button on the DR to save the
Megohm reading. Note: the DR automatically acquires a HiPot reading at 1min/60s
- this value can also be used for the Megohm reading.
Fig 2-6: Megohm & 1 min DC test reading – test active
7) If a DA test is needed, continue to keep the Test button pressed. At 3min/180s, the
DR will automatically acquire the voltage and current readings and then will
calculate a 3min/30s DA Test as shown below.
Fig 2-7: DA ratio visible

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Fig 2-8: Test active - Megohm, DA & PI values listed
8) If a PI test is wanted, keep the Test button depressed until the 10 minutes of the
PI test has elapsed. At 10 minutes, the readings for the PI test will automatically be
recorded.
9) If a HiPot test is desired, keep the Test button depressed, change the PP24’s
function knob to the 100uA/div (as shown below) and raise the output voltage to
the required HiPot test voltage.
Fig5-9:HiPot100µA/Div
10) Once at the HiPot test voltage at p, note the time on the tester. Change the current
sensitivity on the tester as noted on the screen of the DR.
11) Once the required time for the HiPot test has elapsed, press the Save HiPot button
on the DR.

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Fig5-10:AtDCtestcompletion
12) Release the Test button and allow the voltage on the PP24’s test leads to drop to
zero before touching the test leads.
13) To save the data just recorded, press the Store button on the DR and select a
record to save the data to. Use the Up and Down buttons to move to the record,
press the Select button to select the record. Once the DC Tests field is highlighted
and press Select again to store the data to the DR’s memory.
Fig 2-11: Storage Screen

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