Megger PPX30 User manual

Baker Power Packs
PPX30, PPX30A, PPX40
User Guide

Baker Power Packs
PPX30 PPX30A PPX40
User Guide
Part number: 71-061RC EN
Revision: V2
Publication date: August, 2019
Copyright © 2019 Megger Baker Instruments
All rights reserved.
Megger Baker Instruments
4812 McMurry Avenue
Fort Collins, Colorado 80525 USA
Telephone: [phone] (USA Only)
Fax: [phone]
Email: [e-mail] [e-mail]
Web: https://us.megger.com/products/motor-and-generator-testing
Information furnished in this manual is believed to be accurate and reliable. However, Megger Baker Instruments
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
Megger Baker Instruments.
NOTICE: No part of this document may be reproduced in part or in full by any means, such as photocopying,
photographs, electronic recording, videotaping, facsimile, and so on without written permission from Megger Baker
Instruments.
Megger Baker Instruments assumes no liability for damages consequent to the use of this product.
CAUTION: Please read and thoroughly understand the contents of this entire guide before using this product.
Failure to follow the instructions and safety precautions in this manual can result in serious injury, damage to the
product, damage to other equipment, or a malfunctioning system. Keep this guide in a safe and ready location for
future reference.
Notices
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Electrical and Calibration Standards
All Megger Baker Instruments standards are either certified directly or are traceable to certification by the National
Institute of Science and Technology, formerly the United States Bureau of Standards. To obtain other information
concerning calibration, contact Megger Baker Instruments.
Megger Acquisition of Baker Instruments
Megger Group Limited, a manufacturer of electronic test equipment and measuring instruments for power
applications, acquired the Baker Instruments business from SKF Group in August of 2018
For over 50 years, the Baker Instruments business has led the electrical motor testing industry and has a recognized
leading brand and position in this area. As such, legacy products will carry the Baker Instruments or SKF brands,
which will be supported by Megger moving forward.
Trademarks
Megger is a registered trademark of Megger Group Limited.
All other trademarks are the property of their respective owners.
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 if it 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 is required to
correct the interference.
Due to the phenomena being observed and the material properties being measured, this equipment radiates radio
frequency energy while in active test mode. Care should be taken to make sure this radio frequency energy causes
no harm to individuals or other nearby equipment.
Notices
ii Baker Power Packs User Guide 71-061RC EN V2 www.megger.com

Declaration of Conformity
Megger Group Limited—Baker Instruments
4812 McMurry Ave. Suite 100
Fort Collins, CO 80525 USA
Equipment Description: Testers for Surge and DC Hi-Pot of electric motors.
Equipment Model Designations: PPX
Application of Council Directive DIRECTIVE 2014/35/EU on the harmonization of the laws related to Member States
relating to electrical equipment designed for use within certain voltage limits and Council Directive 89/336/EEC on
the approximation of the laws related to Member States relating to the electromagnetic compatibility, as amended
by: Council Directive 93/68/EEC. Note: due to the phenomena being observed and the material properties being
measured, this equipment does radiate radio frequency energy while in the active test mode. Directive 2011/65 / EU
- RoHs standard.
Referenced Safety Standards
EN 61010-1:2010 Third Edition
Referenced EMC Standards
EN 61326-1:2013, FCC Part 15 Subpart B:2018 IEC & EN 61000-4-4: 2012
ICES-003 Issue 6:2018 IEC 61000-4-5:2005
EN 61326-1:2013 EN 61000-4-5:2006
EN 55011:2009+A1:2010 IEC & EN 61000-4-6:2013
CISPR 11:2009+A1:2010 IEC 61000-4-8:2009
IEC 61000-4-2:2008 EN 61000-4-8:2010
EN 61000-4-2:2009 IEC & EN 61000-4-11:2004
IEC & EN 61000-4-3:2006/A1:2008/A2:2010
I, the undersigned, hereby declare that the equipment specified above conforms to the above Directives and
Standards.
Signature:
Printed Name: Craig Powers
Title: Quality and CI Leader
Notices
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Notices
iv Baker Power Packs User Guide 71-061RC EN V2 www.megger.com

Contents
1 — User Safety and General Operation........................................................................1
Safety Precautions...................................................................................................................... 1
General Safety Warnings............................................................................................................. 1
Safety, Hazard, and Warning Symbols on the Instrument ...................................................... 2
Test Related Warnings................................................................................................................. 2
Equipment Stop Button............................................................................................................. 3
2 — Baker Power Pack Introduction...............................................................................5
Instrument Notices..................................................................................................................... 5
General ...................................................................................................................................... 5
Power Pack Features Overview ................................................................................................. 6
PPX Indicator Lights .................................................................................................................... 6
PPX40 Front Panel Controls......................................................................................................... 7
PPX30/30A Front Panel ............................................................................................................... 8
PPX30/30A Three-Phase Test Lead Selector Switch ..................................................................... 9
PPX Tester Angle Adjustment ...................................................................................................... 10
PPX30/30A Configuration.......................................................................................................... 11
PPX30/30A Internal Leads Configuration..................................................................................... 11
PPX30/30A Configuration for DC HiPot Tests—Three-Phase Test Leads ....................................... 12
PPX30/30A Configuration for Surge Tests—Three-Phase Test Leads............................................. 13
PPX40 Configuration ................................................................................................................. 14
PPX40 Internal Leads Configuration ............................................................................................ 14
PPX40 Configuration for DC HiPot Tests—Single-Phase Test Leads .............................................. 14
PPX40 Configuration for Surge Tests—Single-Phase Test Leads.................................................... 14
Baker PPX40 Manual Surge Range Switch................................................................................... 15
3 — Baker Power Pack Setup .........................................................................................17
Baker DX to Power Pack Setup.................................................................................................. 17
Baker AWA to Power Pack Setup.............................................................................................. 19
4 — Using Power Packs with Baker AWA Testers.........................................................21
Combining Baker AWA-IV Host and Power Pack Tests ............................................................ 21
Creating Test and Motor IDs, and Setting Up the Tests........................................................... 22
Create a New Test ID................................................................................................................... 22
Define Test Parameters for the Test ID ......................................................................................... 23
Create a New Motor ID............................................................................................................... 25
Running the Combined Baker AWA-IV and Power Pack Tests ................................................ 26
Single-phase Testing—PPX30/30A Combined with Baker AWA Tester .................................. 31
Single-coil Testing ...................................................................................................................... 32
Go/No Go Surge Testing ............................................................................................................. 32
Single-coil Testing Using a Test Reference.................................................................................... 37
Low-impedance Armature or Coil Testing Using the Baker PPX30A ...................................... 42
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PPX30A Configuration for Armature (Low-impedance Device) Tests ............................................ 42
Armature Testing Fixture Attachment .......................................................................................... 43
Low-impedance Armature or Coil Test Procedures for PPX30A .................................................... 44
Setting up an Armature Surge Test.............................................................................................. 45
Running the Manual Armature Surge Test Using the Baker AWA and PPX30A.................... 48
5 — Using Power Packs with Baker DX Testers ............................................................51
Combining a Baker DX Host and Power Pack for Testing ....................................................... 51
Running the Combined Baker DX and Power Pack Tests ........................................................ 52
DC Test Procedures When Using Power Packs.......................................................................... 52
Surge Test Procedures When Using Power Packs ..................................................................... 57
Baker PPX30/30A Three-Phase Testing......................................................................................... 57
Baker PPX40 Three-Phase Testing................................................................................................ 57
Surge Test Example Process......................................................................................................... 57
Low-impedance Armature or Coil Testing Using the Baker PPX30A ...................................... 61
Low-impedance Armature or Coil Test Procedures for PPX30A .................................................... 61
Appendix A — Maintenance..........................................................................................67
Product Care .............................................................................................................................. 67
Routine Inspection ...................................................................................................................... 67
Cleaning..................................................................................................................................... 67
Care of the Instrument................................................................................................................ 67
Test Leads ................................................................................................................................... 67
Power Pack Lifting and Shipping .............................................................................................. 68
Lifting the instrument—PPX models............................................................................................ 68
Appendix B — Troubleshooting.....................................................................................69
Self-help and Diagnostics .......................................................................................................... 69
Basic Information ....................................................................................................................... 69
Equipment Return...................................................................................................................... 69
Appendix C — Recommended Test Voltages ................................................................71
Recommended DC Voltages for Insulation Resistance Test ..................................................... 71
Recommended DC HiPot and Surge Test Voltages................................................................... 71
Appendix D — Specifications.........................................................................................73
Electrical Specifications.............................................................................................................. 73
General Specifications................................................................................................................ 73
Environmental Specifications .................................................................................................... 73
Appendix E — Accessories and Equipment...................................................................75
Optional Accessories .................................................................................................................. 75
vi Baker Power Packs User Guide 71-061RC EN V2 www.megger.com

1 — User Safety and General Operation
Safety Precautions
Read and follow all safety precautions and safe operating practices in your guide. Do not exceed maximum operating
capabilities of the Baker Power Packs, or the Baker AWA and Baker DX testers used with these units.
The general safety information presented here is for both operating and service personnel. You will find specific
warnings and cautions throughout this guide where they apply.
If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment
may be impaired.
WARNING: Failure to heed the following safety precautions can result in injury or death from severe
electrical shock.
General Safety Warnings
Do not remove the product covers or panels, or operate the tester without the covers and panels properly
installed. Components on the inside of the tester carry voltage for operation and can render a shock if touched.
Use appropriate safety equipment (such as high-voltage gloves, eye protection, and more) as required by your
organization and governing regulatory agencies.
The devices covered in this guide are not waterproof or sealed against water entry.
The devices covered in this guide are intended for indoor use. If using outdoors, you must protect the device(s)
from rain, snow, and other contaminants.
Repairs and repair parts warning: Replacement or repair of parts within the unit should be conducted only by
Megger Baker Instruments authorized service personnel. Opening a unit may void the warranty. Authorized
service personnel will replace defective, damaged or broken test leads with factory-authorized parts to ensure
safe operation and maintain performance specifications.
Ground the product: The devices covered in this guide are grounded through the power cord’s grounding
conductor. To avoid electrical shock, plug the power cord into a properly wired/grounded receptacle before
connecting the product test leads.
In addition to the power supply cable ground, the power packs have a black ground test lead that serves as the
motor frame return path for testing. They also have a black braided ground lead to provide a sufficiently low
impedance ground path adequate to carry the current flow for the worst case internal ground fault.
WARNING: DANGER FROM LOSS OF GROUND. Upon loss of the protective ground connection, all
accessible conductive parts—including knobs and controls that may appear to be insulated—could cause
electrical shock!
NOTICE: The ground-fault systems on the Baker AWA-IV and Baker DX hosts require a proper ground for the tester
to operate properly in all modes. When the Baker AWA-IV or Baker DX tester is used as a host to a power pack,
improper grounding can also affect operation of the power pack
User Safety and General Operation
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Safety, Hazard, and Warning Symbols on the Instrument
Table 1: Safety and hazard icons on the instruments outer case.
Icon Description
Warning about hazardous voltage and risk of injury or death from severe electrical shock.
Located above Leads Energized LED and near other voltage input or output elements.
Ground. Located on rear panel of instrument below ground terminal.
High voltage warning label. Located on the left side panel below the on/off switch and
power inlet/outlet connectors.
Test Related Warnings
Before connecting test leads, verify that circuits are not energized. Never connect the Baker Power Pack or
host tester units to an energized circuit.
Before connecting test leads, disconnect all external devices (such as capacitors and surge arrestors) from the
test circuit.
Two-party operation is recommended only when using proper equipment (such as the remote E-Stop) and when
taking appropriate precautions so that both operators are fully aware of all conditions at all times.
Always know what test is being performed and when test leads are energized. For example, do not adjust test
leads when operating a footswitch. Leads will have live voltage and severe electrical shock can result.
Upon completion of any Megohm, dielectric absorption (DA), polarization index (PI), DC HiPot, or Step Voltage
tests, be sure to short the winding to ground and allow sufficient time for discharge before disconnecting the
test leads. If you do not do this, voltage can build up on the winding. Some industry standards suggest allowing
a winding to discharge four times the total amount of time that DC voltage is applied to the winding. For
example, IEEE 95 suggests allowing a winding to discharge four times the total amount of time that DC voltage
is applied to the winding and no less than 2 hours.
If it is necessary to remove the tester leads prior to complete discharge of the circuit under test, short and
ground all leads using an appropriate jumper cable prior to removal of the test leads.
Make sure to disconnect the tester leads before energizing or powering up the motor.
Never attempt to test a winding with both host and power pack leads attached to the winding at the same time.
Damage to the tester will occur.
User Safety and General Operation
2 Baker Power Packs User Guide 71-061RC EN V2 www.megger.com

Equipment Stop Button
The Baker Power Packs are equipped with a red Equipment Stop (E-Stop) button on the front panel of the unit. Use
it to quickly discontinue a test and to shut off power to the power pack’s high-voltage circuitry.
The button will remain locked in position until manually retracted by rotating the Equipment Stop button clockwise.
Fig 1: Baker Power Pack showing Equipment Stop button.
Item Description
1 Equipment stop button
2 Front panel
Only Megger Baker Instruments supplied test leads designed for this instrument provide the full safety rating.
User Safety and General Operation
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Baker Power Pack Introduction
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2 — Baker Power Pack Introduction
Instrument Notices
CAUTION: Be sure to comply with all safety and proper operating procedures when setting up the tester and power
packs, and when using them in testing. Failure to do so can result in injury to personnel or damage to equipment.
General
The host testers are equipped with open ground/ground fault monitors and indicators. This circuitry should not
hinder operation of GFI protected AC power circuits.
When the analyzer is plugged into the power pack as described later in this guide, it gets its AC power from the
power pack; so if the power pack is unplugged, the analyzer will also turn off.
Before use:
Do not allow the analyzer’s test leads to lie anywhere near the power pack test leads. The unit’s leads should
coil on top of the unit or loop on the power pack handle. Otherwise, the leads could interfere with tester
measurements.
Make sure the analyzer’s test leads are not connected together.
Make sure the analyzer’s (host) ground test lead is not grounded when conducting tests using a power pack.
Make sure no printer is hooked up to the USB port.
During use:
Do not switch the test leads or change the Test Select switch while a test is in progress.
If you need to use the host unit in standalone mode, turn off the power pack, ensure that the analyzer’s AC
input is plugged into a properly grounded source, and disconnect the communications cable between the
analyzer and the power pack. If the communications cable between the analyzer and the power pack remains
connected and the power pack is turned off, the I/O lines will be influenced and will cause problems with the
analyzer’s operation.
NOTICE: A power pack is purchased with, and calibrated to, the Baker DX or Baker AWA-IV tester host that it is
shipped with.
Baker Power Pack Introduction
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Power Pack Features Overview
PPX Indicator Lights
PPX power packs have six indicator lights across the top of the front panel. Their functions are listed in the table
below.
Fig 2: PPX indicator lights; Baker PPX40 shown.
Item Description
1 Leads energized. Indicates that the output has been energized or that more than 45 volts is
present on the output wires.
2 Equipment stop. Indicates the front panel E-STOP button has been pushed. The LED will flash
once a second until the E-STOP button has been reset.
3 Remote E-Stop. Indicates the Remote E-STOP button has been pushed. The LED will flash once
a second until the E-STOP button has been reset.
4 Power on. Indicates when the AC power is turned on to the unit.
5 Arc detect. Indicates an arc has occurred (HiPot failure). The LED will flash for approximately
five seconds.
6 Overcurrent trip. Indicates an overcurrent (HiPot) failure – current exceeded approximately 1.2X
the max for each scale (for example, 1.2 mA in the 100 uA range) during a HiPot test. The LED
will flash for approximately five seconds.
7 On the PPX40, the Surge range switch has a green indicator light for the 25–40K range (circled
in image). Indicates when the high range has been selected. When this LED is blinking, the
range switch has been moved to the low range and the setpoint is out of the surge voltage
range.
Baker Power Pack Introduction
6 Baker Power Packs User Guide 71-061RC EN V2 www.megger.com

PPX40 Front Panel Controls
The PPX front panel controls are similar to their PP model counterparts. The differences include:
A new Ramp Rate Selector switch that allows you to choose how quickly voltage will ramp.
A redesigned Surge Range switch on the PPX40 model.
An LED arch above the Voltage Output Control knob.
E-STOP LEDs indicating when the E-Stop is engaged.
Arc and overcurrent LEDs.
Fig 3: PPX front panel controls; Baker PPX40 shown.
Item Description
1 Push to Test (PTT) button enables the output voltage when pressed.
2 E-Stop button turns off the power to the high-voltage power supply and returns the relays to
the safe default position, disabling the output and shorting the output lead.
3 Surge range selector switch (PPX 40 only) selects the output voltage range for surge mode and
which pulsing assembly is used.
4 Ramp rate selector switch allows you to control how quickly voltage will ramp when the
Voltage Output Control Knob is turned. Refer to the table below for specifications.
5 Function Selector switch selects the operational function of the unit, Surge, HiPot (100µA/Div,
10µA/Div, 1µA/Div, Armature test (PPX 30A only).
6 Voltage Output Control knob increases or decreases the output voltage when turned and held.
Turn clockwise to increase the output voltage and counter clockwise to decrease.
When the Push To Test button is released, the setpoint is automatically reset to zero—with the
exception of when the Zero Start override feature is used in Surge mode.
7 Zero-start override. This key switch overrides the Zero Start function and allows the unit to
immediately apply the full target voltage level to the test leads. With the key in the vertical
position, testing starts at zero volts and must be ramped up to the target voltage level. In the
horizontal key position, zero-start override is enabled.
Table 2: Ramp Rate Selector switch positions, voltage increments, and ramping times.
Position Volts/second Time to Full Voltage (seconds)
1 2000 15
2 1000 30
3 500 60
4 250 120
5 125 240
6 63 480
Baker Power Pack Introduction
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PPX30/30A Front Panel
The Baker PPX30 and PPX30A front panel is similar to the PPX40 except that it does not have a Surge Range switch.
The Function Selector switch on the PPX30A includes a low-impedance test feature (signified by an armature icon)
as shown in the example below.
The Baker PPX30 and PPX30A power packs also feature a Test Select switch just below the handle so you can select
the test type or test lead needed.
Fig 4: PPX front panel controls; Baker PPX30A shown.
Item Description
1 Function Selector switch.
2 ARM test mode (Low-impedance device testing such as armatures, DC field coils, and
interpoles). Employs the Baker ZTX impedance matching transformer circuitry built into the
PPX30A.
3 Surge test mode.
4 DC HiPot test mode.
5 Test Select switch.
Baker Power Pack Introduction
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PPX30/30A Three-Phase Test Lead Selector Switch
The Baker PPX30 and PPX30A power packs are supplied with three-phase test leads. The Test Select switch is used
to switch between the different test options HiPot or Surge, and to select the test leads (1, 2, 3) energized during
Surge testing. The Test Select switch also has a LEADS GROUND position.
Fig 5: Three-phase lead Test Select switch.
Item Description
1 Test Select switch.
2 Leads ground position. Used to discharge device under test after completing DC tests.
3 Surge test mode; select from test leads 1, 2, and 3.
4 DC HiPot test mode.
5 Do not rotate the Test Select switch from the HiPot to the Lead 3 position.
With the PPX30/30A three-phase test lead configuration, you are only required to connect the three leads once to the
motor being tested.
CAUTION: Do not switch the Test Select switch while a test is in progress; this may substantially reduce
the switching element’s useful life.
Baker Power Pack Introduction
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PPX Tester Angle Adjustment
The Baker PPX model power packs feature a plate on the top that you can use to adjust the viewing angle of the
attached host unit.
If you decide to use this feature, remove the host unit from the power pack then adjust both left and right sides to
the same height then securely tighten the wing bolts.
Reattach the host unit, ensuring that the safety strap is used to secure the unit.
Fig 6: PPX tester angle adjustment plate; Baker PPX30A shown.
Item Description
1 Right wing bolt (viewed from front).
2 Safety strap.
3 Tester adjuster angle plate.
4 Left wing bolt.
CAUTION: Ensure that both wing bolts and the safety strap are all securely tightened before using the tester in this
manner. Keep all tools and body parts out of area below the adjustment plate to prevent damage or injury.
Baker Power Pack Introduction
10 Baker Power Packs User Guide 71-061RC EN V2 www.megger.com

PPX30/30A Configuration
PPX30/30A Internal Leads Configuration
Three output cables (orange, brown, and yellow cables for phases 1, 2, and 3 respectively) with insulated jacket
rated at 60 kV DC, appropriately marked.
One black ground cable with insulated jacket rated at 60 kV DC, appropriately marked.
One black ground cable with braided jacket, appropriately marked.
Table 3: Baker PPX30/30A internal connections during HiPot testing.
Test Select
Position
Test Lead 1
Orange
Test Lead 2
Brown
Test Lead 3
Yellow
Ground Lead
Black
Black Braid
HiPot High Voltage Open Open Ground Ground
Table 4: Baker PPX30/30A internal connections during Surge testing.
Test Select
Position
Test Lead 1
Orange
Test Lead 2
Brown
Test Lead 3
Yellow
Ground Lead
Black
Black Braid
Test Lead 1 High Voltage Ground Ground Ground Ground
Test Lead 2 Ground High Voltage Ground Ground
Test Lead 3 Ground Ground High Voltage Ground
NOTICE: For Baker PPX30/30A power packs, you must place the power pack control panel Function Selector switch
into the HiPot position to perform a HiPot test. Be sure to switch the power pack Test Select switch to the HiPot
position. Both switches must be in their correct positions when performing the test. If these switches are not set
properly, the tests will not perform correctly and the data recorded will be erroneous.
Baker Power Pack Introduction
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PPX30/30A Configuration for DC HiPot Tests—Three-Phase Test Leads
For the Baker PPX30/30A, you need only connect the power pack’s test leads to the motor leads once. The power
pack’s Test Select switch internally configures the test leads for HiPot and Surge testing.
1. Ensure that the power pack setup procedure described earlier has been followed.
2. Set the Function Selector switch to 100 µA/div for HiPot testing.
Fig 7: Power pack DC HiPot test settings; Baker PPX30A shown.
Item Description
1 Function Selector switch.
2 Set to 100 µA/div for HiPot testing.
3 Test Select switch.
4 Set to LEADS GROUND before connecting test leads.
5 Set to HiPot for testing.
3. Set the Test Select switch to LEADS GROUND (ground icon).
4. Connect the power pack test leads to the motor leads as described in the table below.
Table 5: Baker PPX30/30A device under test connections for HiPot and Surge testing.
Test Lead 1
Orange
Test Lead 2
Brown
Test Lead 3
Yellow
Ground Lead
Black
Black Braided
Safety Lead
Motor phase A Motor phase B Motor phase C Motor frame Station/earth ground
5. Power up the host unit and the power pack. Set the Test Select switch to HiPot. When selecting HiPot testing,
you will hear a loud noise as the high-voltage relay makes contact.
6. Check that the open ground detect warning banner does not appear in the Baker DX Display Area, or that the
open ground detection light on the Baker AWA is not illuminated.
Baker Power Pack Introduction
12 Baker Power Packs User Guide 71-061RC EN V2 www.megger.com