Baker D30R Training manual

D30R Users Manual
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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

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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.

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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

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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

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Safety Precautions
Note: The general safety information presented here is for both operating and
service personnel. Specific warnings and cautions will be found throughout this
manual where they apply.
•Do NOT touch the test leads, winding or component under test while a test
is being performed. Severe electric shock may result.
•Never attempt a two-party operation. Always know what test is being
performed and when.
•Never attempt to test an energized motor.
•Be sure the surge test instrument is grounded. Use a three lead grounded
supply (or an extra ground lead if unsure of supply ground).
•For capacitor start motors or systems with surge arrestors/power factor
correction capacitors; be sure to disconnect all capacitors from the test
circuit before testing.
•The surge test is NOT approved for use in an explosive environment.
•Upon completion of a DC High Potential test, short the winding, motor,
etc., to ground and allow time for discharge before disconnecting the test
leads.
•Ensure the tester leads are disconnected before the motor is energized or
powered up.
•Do not operate the tester without the covers and panels properly installed.
Power Source Precautions
DANGER
High-voltage test equipment should be handled with
CAUTION. High-voltage test procedures should be followed, including
the use of high-voltage gloves!
Operation of the tester by persons who are using a pacemaker may present
unusual safety risks. Such person should take special precautions!

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This product is intended to operate from a power source that applies 85-264
VAC RMS 50/60Hz between the supply conductor or between either supply
conductor and ground.
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.
Terms & Symbols
•Caution statements identify conditions or practices that could result in
damage to the equipment or other property.
•Warning/Danger statements appearing in boxes identify conditions or
practices that could result in personal injury or loss of life.
•Notices that are bolded indicate operational cautionary information.
•Notes: are important information and hints on the operation of the
equipment.
Warranty Notes
Important notice concerning the Warranty and Repairs
The warranty is Void if tester is shipped in any container other than the original
container it was shipped in or factory specified packaging. For replacement
factory specified packaging and instructions for proper shipment of the tester see
the Shipment section at the end of this chapter. Also, be sure to complete the
Warranty Return Form when sending the tester to Baker Instrument
Company.
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 render an electric shock!

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If there is a failure of the Baker tester, regardless of whether it is under warranty
or not, the customer should Call the Baker Instrument Company Service
Department BEFORE returning the unit for repair. In some cases, the
repair may be done by the customer at significant savings. If under warranty,
the customer may still save costly shipping charges and lost time while the unit
is being shipped and repaired. Our service staff may also direct the customer to
ship the unit to one of our Authorized Service Centers for repairs.
When calling the Baker Service Department or one of the Service Centers,
please have the Model and Serial Numbers (located on the rear panel of the unit)
available. If the unit is out of warranty, a purchase order will be required if the
unit is returned for repair.
The Baker Instrument Company Service Department phone number is 800-752-
8272 or 970-282-1200.
Authorized Service Centers
Europe Baker Instrument GmbH 49-911-984600
Hutbergstrasse 21 49-911-832169
D-90475 Nurnberg 50
West Germany
United States Baker Instrument Company 970-282-1200
4812 McMurry Avenue 970-282-1010
Fort Collins, CO 80525 800-752-8272
Training Seminars
Extensive training seminars are conducted by Baker Instrument Company to
help the user get the most out of the Surge/HiPot Tester in a wide variety of
applications. In-House Seminars are available at plant/shop site. In these
seminars, tailor the training for your specific needs. Please contact the Sales
Department at Baker Instrument Company, 800-752-8272 or 970-282-1200 to
schedule an In-House Seminar.
Environmental
The tester should only be operated in temperatures ranging from 0 to 100
degrees Fahrenheit (-17.8 to 37.8 degrees Celsius).

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Due to corrosion, humidity will affect the condition of the instrument’s
components over time. The storage environment of this instrument should be
less than 50% humid. The instrument certainly should not be stored in any
location where water entry could occur as the instrument is NOT waterproof.
Due to the possibility of arcing in the test leads or in the motor being tested, the
D30R is NOT approved for use in an explosive environment.
Shipment
All Baker testers are shipped using factory foam-filled containers. Should the
tester be returned to Baker Instrument Company for any reason, we recommend
using the original packaging the unit came in or the following factory specified
packaging:
Contact Baker Instrument Company to order factory-specified packaging for the
testers. Baker Instrument Company is not responsible for damage due to
shipping testers back to the factory in inadequate materials.
List of Items Furnished
•1 each – Surge Tester with attached test leads
•1 each – Removable line power cord
•1 each – Set of removable Resistance Test Leads
•1 each – Instruction Manual

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CHAPTER 2: INSTRUMENT OVERVIEW
Inside…..
•Front Panel Controls
•Initial Tester Power Up & Checkout

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Digital Front Panel Diagram
D30R
21

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Front Panel Controls
1) PRINTER PORT
Parallel port for printing waveforms and summaries displayed by the
Digital Tester. This port may also be used for interfacing with the
Motor Test Acquisition for Windows program (MTA for Windows) on
a personal computer.
2) FUNCTION KEYS
Function key for data collection, recall, and printing of tests. The keys
correspond to choices provided on the CRT display below them. See
the chapter on Storage and Print Capabilities, for a detailed description
of the tester’s storage capablility.
3) CRT DISPLAY
The Cathode Ray Tube (CRT) is the location where the tester displays
test information. At the Top, menus corresponding to the four function
keys above the CRT are shown. The main portion of the screen displays
the waveforms being measured and/or recalled with corresponding
graticules for reference. The bottom portion shows the volts/division
for the waveform, the name of the test on display, and the micro-
seconds/division (micro-amps/division for hipot tests). When using the
function keys, the screen will display options pertinent to the storage,
recall, and print capacities of the unit. Error messages are also
displayed here.
4) LINE IN
The external AC power-supply plug.
5) ON/OFF
The on off switch for the unit. On/off switch is combined with the AC
power entry and a fuse.
6) TEST
The TEST button activates the high voltage output of the tester. One of
the selected modes, Surge, or Hipot will be enabled and a voltage will
be impressed on the device being tested. This button automatically
disengages when released.

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7) OPEN GROUND WARNING LIGHT
When the AC line source is not properly grounded, the red Open
Ground light will illuminate. The test set will power up, but high
voltage will be withheld by internal electronics.
8) HIPOT TRIP WARNING LIGHT
This lamp illuminates to indicate a DC HIPOT trip circuit has stopped
the test. The red lamp will stay illuminated until the TEST button is
released.
9) INTENSITY
Rotation of this control will adjust the intensity or brightness of the
display. Clockwise (CW) will increase intensity. Counterclockwise
(CCW) will decrease intensity. Intensity has a slight effect on the focus
and can be adjusted to a blank screen.
10) VERTICAL POSITION
This control adjusts the up or down positioning of the surge wave
pattern. Optimum positioning is usually on the center of one major
graticule line below center for surge testing.
11) HORIZONTAL POSITION
This control adjusts the side to side positioning of the surge wave
pattern. A trace beginning at the far left is suggested for surge testing.
12) FUNCTION SELECTOR
This control selects the type of test to be performed and the sensitivity
of the DC HiPot leakage current display. The name of the test chosen
is displayed on the lower portion of the CRT for reference. There are
four primary position as follows.
•AUX: The auxiliary position is for the D30R is used for Surge and
HiPot modes.
•SURGE: This position selects the Surge Test. The name of the test
and the microseconds per division measured is displayed on the
lower portion of the CRT for reference. A digital readout for the
peak voltage of the test is also displayed in the upper right portion
of the screen for reference.
•HIPOT- uA/dIV: This position is used for DC HiPot testing. The
name of the test is displayed on the lower portion of the CRT for
reference. A digital readout for the leakage current (in micro-amps)

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of the test and the resultant resistance in mega-ohms is also
displayed on the screen for reference. There are three positions
associated with the HiPot test. The three positions are 100uA/div,
10uA/div, and 1uA/div. The chosen micro-amps per division
setting is displayed on the lower right portion of the CRT for
reference during testing u-Amps/Div controls the sensitivity of the
current displayed. It also automatically selects the overcurrent trip
point, which will be ten times these settings or 1000, 100, and 10
micro-amps respectively.
13) VOLTS/DIV
This control sets the sensitivity of the display or scale factor in volts per
division for both the Surge and DC HIPOT traces. There are four
settings corresponding to 1250, 2500, 5000, and 7500 volts per
division. Note: this knob setting does not limit the output voltage of the
tester.
14) SECONDS/DIV
This control adjusts the seconds per division or sweep rate of the trace
on the horizontal axis of the surge display. There are ten settings
corresponding to 2, 6, 10, 20, 60, 100, 200, 500, micro-seconds and 1
and 2 milli-seconds per division. The seconds per division setting is
displayed on the lower right portion of the display for the reference
during Surge Testing. This control will have the effect of zooming in or
out on the wave pattern.
Caution
For the surge test, with the SECONDS/DIV control at the
lowest possible setting, the ringing pattern must be at lease
one division in length for one full cycle. Less than one
division for the first cycle indicates a very low inductive
load. DAMAGE to the instrument is possible when
operated more than ten (10) seconds into a low
inductive load.