Baker D30R Training manual

D30R Users Manual
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Do Not Touch Test Leads while test is in Progress!
71-023 Rev C 5/8/2007
Users Manual
Digital Surge/DC HiPot/Resistance Tester
Models D30R
Baker Instrument Company
4812 McMurry Avenue
Fort Collins, CO 80525
[phone]
[phone] FAX
[phone] USA Only
www.bakerinst.com

D30R Users Manual
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Do Not Touch Test Leads while test is in Progress!
71-023 Rev C 5/8/2007

D30R Users Manual
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Do Not Touch Test Leads while test is in Progress!
71-023 Rev C 5/8/2007
Warranty
Baker Instrument Company (Baker) warrants title to the product and also
warrants product on date of delivery to purchaser to be of the kind and quality,
merchantable and free of defects in workmanship and material. There are no
warranties which extend beyond those expressly stated in this contract.
If within one year of shipment by Baker of any item of the product, purchaser
discovers that such item was not as warranted and promptly notifies Baker in
writing thereof, company shall remedy such non conformance by, at company’s
option, adjustment or repair or replacement of the item and any affected part of
the product. Purchaser shall assume all responsibility and expense for removal,
reinstallation, freight, and on-site service in connection with the foregoing
remedies. The same obligations and conditions shall extend to replacement
parts furnished by Baker hereunder.
Baker’s liability to purchaser relating to the product whether or in tort arising
out of warranties, representations, instructions, installations, or defects from any
cause, shall be limited exclusively to correcting the product and under the
conditions as aforesaid.
Any separately listed item of the product (such as tubes) which is not
manufactured by Baker, shall be covered only by the express warranty of the
manufacturer thereof.
Information furnished in this manual by Baker is believed to be accurate and
reliable. However, Baker assumes no responsibility for the use of such
information nor 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.
Warning: Baker 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,
Fort Collins, Colorado.

D30R Users Manual
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D30R Users Manual
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Table of Contents
Warranty......................................................................................................3
PREFACE...........................................................................................................9
SAFETY PRECAUTIONS.................................................................................... 11
POWER SOURCE PRECAUTIONS ....................................................................... 11
GROUND THE PRODUCT .................................................................................. 12
TERMS &SYMBOLS ........................................................................................ 12
WARRANTY NOTES......................................................................................... 12
Important notice concerning the Warranty and Repairs............................12
AUTHORIZED SERVICE CENTERS .................................................................... 13
TRAINING SEMINARS ...................................................................................... 13
ENVIRONMENTAL ........................................................................................... 13
SHIPMENT ....................................................................................................... 14
List of Items Furnished...............................................................................14
CHAPTER 2: INSTRUMENT OVERVIEW ...............................................15
FRONT PANEL CONTROLS ............................................................................... 18
INITIAL POWER-UP AND CHECK-OUT ............................................................. 22
ASELF-TEST PERFORMED ON THE TESTER FOR ALL INTERNAL MEMORY MODULES
WHEN THE TESTER IS POWERED UP.ANY FAILURES WILL BE NOTED ON THE CRT
DISPLAY.......................................................................................................22
CHAPTER 2: RECOMMENDED TEST SEQUENCE, VOLTAGES AND
TESTING PRECAUTIONS............................................................................23
RECOMMENDED TESTING SEQUENCE.............................................................. 25
1. Coil Resistance Test..............................................................................25
2. Megohm Test.........................................................................................25
3. Principles of the Dielectric Absorption (DA) Test.................................26
4. Principles of the Polarization Index (PI) Test........................................26
5. DC HiPot Test.......................................................................................27
6. Surge Test..............................................................................................27
RECOMMENDED TEST VOLTAGES –DC HIPOT AND SURGE TESTS ................. 28
IEEE 95-1977................................................................................................. 28
IEC 34-15....................................................................................................... 29
APPLICABLE STANDARDS ............................................................................... 29
CHAPTER 3: COIL RESISTANCE TESTING...........................................33
PRINCIPLES OF COIL RESISTANCE TESTING .................................................... 35
Resistance Test Display..............................................................................35
Resistance Test Checklist...........................................................................35
Resistance Test Checklist...........................................................................36

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Auto Ranging Resistance Measurement Algorithm....................................37
Saving & Recalling Measurements............................................................37
Indications of problems in a motor............................................................38
CHAPTER 4: PRINCIPLES & THEORY OF DC TESTING....................39
PRINCIPLES OF DC TESTING ........................................................................... 41
CHAPTER 5: PERFORMING HIGH VOLTAGE DC TESTS .................45
THE TEST DISPLAY ......................................................................................... 47
GENERAL USER CAUTIONS AND NOTES .......................................................... 47
TEST PRECAUTIONS ........................................................................................ 48
HIGH VOLTAGE DC TEST CHECKLIST............................................................. 49
DC Testing.................................................................................................49
Full DC Testing of a Motor........................................................................49
Performing Only a Megohm Test........................................................... 53
Performing Only DC Over Voltage Test (DC HiPot Test).........................54
Sample Data showing Good & Poor Insulation.........................................55
Storing the Test Results in Memory............................................................56
USING THE FOOT SWITCH ............................................................................... 57
THE HIPOT OVER CURRENT TRIP INDICATOR................................................. 58
EFFECTS OF TEMPERATURE ............................................................................ 58
Step Voltage Test........................................................................................59
Step Voltage Test Procedure......................................................................59
CHAPTER 6: PRINCIPLES AND THEORY OF SURGE TESTING......61
PRINCIPLES OF SURGE TESTING ...................................................................... 63
Surge Testing Theory .................................................................................63
Determination of a Fault............................................................................65
Motivation for Surge Testing .....................................................................65
Contact Bounce..........................................................................................66
Lightening Strikes ......................................................................................66
Inverter Transients.....................................................................................66
Line Surges.................................................................................................66
IGBT SWITCHING TECHNOLOGY .................................................................... 67
CHAPTER 7: PERFORMING SURGE TESTS...........................................69
GENERAL USER CAUTIONS AND NOTES .......................................................... 71
Surge Test Setup.........................................................................................72
480V THREE PHASE MOTOR CHECK LIST....................................................... 74
SINGLE COIL SURGE TEST AND SET-UP.......................................................... 76
Example: Comparison to a Master Coil ................................................ 78
CHAPTER 8: SURGE TEST APPLICATIONS..........................................81

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MAINTENANCE TESTING ................................................................................. 83
Application Notes.......................................................................................84
SINGLE PHASE MOTORS AND TWO TERMINAL DEVICES ................................. 85
Determination of a Fault............................................................................85
FORM COILS ................................................................................................... 86
Determination of a Fault............................................................................86
Notes and Tips for Form Coils............................................................... 86
THREE PHASE STATORS .................................................................................. 87
Determination of a Fault............................................................................88
TWO OR MORE SINGLE COILS ......................................................................... 88
Determination of a Fault............................................................................89
Notes and Precautions for Two Single Coils.......................................... 89
WOUND ROTOR MOTORS................................................................................ 90
Determination of a Fault............................................................................91
SYNCHRONOUS MOTOR/GENERATOR ............................................................. 92
Determination of a Fault............................................................................92
CHILLER MOTOR TESTING .............................................................................. 93
FIELD COILS ................................................................................................... 93
DC MOTOR/GENERATORS .............................................................................. 93
ARMATURES ................................................................................................... 94
Bar-to-Bar Surge Test................................................................................94
Span Testing...............................................................................................94
Determination of a Fault............................................................................96
Notes and Tips for Span Testing Armatures .......................................... 97
TESTING LARGE AC STATORS/MOTORS ......................................................... 98
Notes and Tips for Large AC Stator/Motors .......................................... 99
ROTOR LOADING (COUPLING)WHEN TESTING ASSEMBLED MOTORS........... 100
TESTING ASSEMBLED MOTORS FROM THE SWITCHGEAR .............................. 102
Notes and Tips for Testing from the Switchgear.................................. 102
TRANSFORMERS............................................................................................ 103
Single Phase Transformers......................................................................103
Three Phase Transformers.......................................................................104
Determination of a Fault..........................................................................105
CHAPTER 9 DOCUMENTING TESTS.....................................................107
Store.........................................................................................................109
Store Record Submenu Options................................................................110
Store Resistance Data..............................................................................110
Store HiPot and PI Data..........................................................................111
Store Surge Data......................................................................................112
STORE Lead Submenu Options................................................................112
Recall .......................................................................................................113
Recall Record Submenu Options..............................................................113

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Recall Resistance Data ............................................................................113
Recall HiPot Data....................................................................................114
Recall Surge Data....................................................................................115
Recall Lead Submenu Options .................................................................115
Print .........................................................................................................116
Clear ........................................................................................................116
Erase........................................................................................................116
COMPATIBLE PRINTER INFORMATION........................................................... 117
Version 3 Firmware .................................................................................117
APPENDIX A: TYPICAL WINDING FAULTS .......................................119
APPENDIX B: TROUBLESHOOTING.....................................................123
SELF HELP AND DIAGNOSTICS ...................................................................... 125
Step #1: Basic Information......................................................................125
Step #2: Applications or Service Problem? ............................................125
APPLICATIONS:WHAT TO DO FIRST!............................................................ 126
Common Application Problems ...............................................................126
Service: What to do First?......................................................129
Open Condition Display...........................................................................129
HiPot Display Checks..............................................................................130
HiPot Over Current Trip Check...............................................................130
Open Ground Check.................................................................................131
Limited Output Surge Waveform..............................................................131
PRECAUTIONS FOR PROPER OPERATION........................................................ 132
WARRANTY RETURN .................................................................................... 132
APPENDIX C: TECHNICAL SPECIFICATIONS AND CALIBRATION
PROCEDURE................................................................................................135
TECHNICAL SPECIFICATIONS ........................................................................ 137
Accuracy of Measurements - Coil Resistance Test..................................138
HiPot Measurement Accuracy – HiPot Voltage.......................................138
Voltage Measurement Accuracy – Surge .................................................138
INDEX.............................................................................................................139

D30R Users Manual
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Do Not Touch Test Leads while test is in Progress!
71-023 Rev C 5/8/2007
PREFACE
Inside…
•Safety Precautions
•Power Source Precautions
•Ground the Product
•Terms and Symbols
•Warranty Notes
•Authorized Service Centers
•Training Seminars
•Environment
•Shipment
•List of Items Furnished

D30R Users Manual
10
Do Not Touch Test Leads while test is in Progress!
71-023 Rev C 5/8/2007