SKF Baker AWA-IV User manual

SKF Static Motor Analyzer
Baker AWA-IV
User manual

SKF Static Motor Analyzer
Baker AWA-IV
User manual
Part number: 71-015 EN
Revision: V11
Copyright © 2014 by SKF USA Inc.
All rights reserved.
SKF USA, Inc.
4812 McMurry Ave. Suite 100
Fort Collins, CO 80525
[phone]
[phone] (FAX)
800-752-8272 (USA Only)
http://www.skf.com/group/products/condition-monitoring/electric-motor-testing/index.html
NOTICE
Baker Instrument Company—an SKF Group Company—assumes no
liability for damages consequent to the use of this product.
SKF Patents
#US04768380 • #US05679900 • #US05845230 • #US05854553 • #US05992237 •
#US06006164 • #US06199422 • #US06202491 • #US06275781 • #US06489884 •
#US06513386 • #US06633822 • #US6,789,025 • #US6,792,360 • US 5,633,811 • US
5,870,699 • #WO_03_048714A1
CAUTION
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC rules. These limits are
designed to provide reasonable protection against harmful interference with
the equipment is operated in its installation.
This equipment generates, uses, and can radiate radio frequency energy
and, if not installed and used in accordance with the product manual, could
cause harmful interference to radio communications. If this equipment
does cause harmful interference, the user will be required to correct the
interference. Due to the phenomena being observed and the material
properties being measured, this equipment radiates radio frequency energy
while in the active test mode. Care should be taken to ensure this radio
frequency energy causes no harm to individuals or other nearby equipment.
Information furnished in this manual by SKF USA, Inc. is believed to be accurate and reliable.
However, SKF USA, Inc. 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 SKF USA, Inc.
SKF USA, Inc. 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 SKF USA, Inc., Fort Collins, Colorado.

Note on software
While the Baker AWA-IV is a Microsoft Windows® based instrument, it is not a computer,
which any software available in the market should be installed. The installed applications and
Windows® configuration are set up to operate the Baker AWA-IV hardware. Modifications to
this setup may cause unit malfunction.
Software license agreement
Baker AWA-IV—test equipment and desktop versions
Carefully read the following terms and conditions before opening the software envelope;
either opening the envelope or using the software constitutes your acceptance of these terms
and conditions. If you, the licensee, do not agree with them promptly, return the package
unopened for a full refund.
Baker AWA-IV programs and documentation are the property of SKF USA, Inc. as copyright
owner. SKF USA, Inc., licenses its software for use; it does not transfer ownership. By the
acts of opening the sealed CD package(s) and making full payment of the required amounts,
the User has been granted a personal, non-exclusive license to utilize the program and
documentation. The term Program refers to both the specific Baker AWA-IV software already
installed on the test equipment (the test equipment version) and to one specific copy of the
desktop version of the Baker AWA-IV software provided in CD form for use on the user’s
separate computer (the desktop version). The term documentation refers to the associated
instructions and reference materials. Both program and documentation also include any
enhancements, modifications, revisions, or additions, which SKF USA, Inc., directly or
indirectly releases to the User.
License
The license granted permits the User to do only the following:
1) Use the test equipment version on only the SKF test equipment provided;
2) Use the desktop version on only a single, approved computer. (The list of approved
computers is available upon request) and only in conjunction with the SKF test
equipment;
3) Use the program and documentation for business and commercial purposes only;
4) Reproduce the program only as necessary to use it and create no more than two
copies of the program in machine readable form for back-up purpose only; and
5) Utilize the documentation only in conjunction with the use of the program.
These are the only rights granted. The user has no right to, among other things: to use the
program on more than one computer or on a computer which has not been approved for use;
to transfer sublicense or rent the program, or to authorize another to do so, or to create
derivative works based upon any part of the program. The rights granted by the licensee shall
terminate (without refund) automatically upon the user’s failure to abide by the terms or
conditions of this license or by any combination by the User to any infringement of any
proprietary rights owned or licensed by SKF USA, Inc.. In the event of any termination, the
user agrees to return all programs, program CD’s, documentation and all copies thereof. In
addition, SKF USA, Inc., from time to time updates its programs and documentation for
registered users. If the user is not registered, it may not receive an update. In the event an
update is received, the user agrees to destroy or return the original program or
documentation and acknowledges that the update will be governed by the terms of this
license also.
ii SKF Static Motor Analyzer—Baker AWA-IV User Manual
Notices

Limited warranty
SKF USA, Inc., warrants to the user for a period of one year from delivery to the original
purchaser that, if properly installed and operated, the program will perform in accordance
with the documentation provided. The User will notify SKF USA, Inc., in writing within ten
days of discovering any error by sending:
1) A list of the command sequence or other input which causes the suspected
repeatable error;
2) A printout or a summary of the result; and
3) The part number and revision of the program.
In the event of any failure of the program to perform substantially in accordance with the
documentation, SKF USA, Inc. agrees to repair or replace, at its sole option, the program or
documentation. In the event such failure cannot be corrected within a reasonable time
frame, a percentage of the price paid by the user attributable to the program will be
refunded.
In no case shall SKF USA, Inc., or its agents be liable for any loss of data, lost profits, special,
incidental, consequential, indirect, or other similar damages arising from breach of contract,
negligence or any other legal theory. In any event, SKF USA, Inc.’s total liability shall be
limited to only a refund of the portion of the price paid attributable to the program. Any
implied warranties including warranties of merchantability or fitness for a particular purpose
are limited in duration to thirty-days (30) from the date of original delivery to the user.
Some jurisdictions do not allow limitations on how long an implied warranty may last on
incidental or consequential damages, so the above limitation may not apply.
SKF USA, Inc. shall be responsible only to the User; no responsibility to any third party shall
be created. This warranty set forth above is in lieu of all other express warranties, whether
oral or written and the remedies set forth above are the User’s sole and exclusive remedies.
The agents, employees, distributors, and dealers of SKF USA, Inc. are not authorized to make
modifications to this warranty or additional warranties on its behalf. Accordingly, additional
statements such as advertising or sales presentations cannot expand or create warranties
and should not be relied upon. This warranty gives specific legal rights along with other
rights, which vary from state to state.
General conditions and covenants
The validity and interpretation of this license agreement shall be governed by Colorado Law
except as to copyright and other proprietary matters, which may be preempted by United
States laws and international treaties. In the event of any violation of this license agreement,
SKF USA, Inc. reserves the right to pursue any state law remedies (including contractual
remedies) or remedies under federal laws or both. The User consents to exclusive
jurisdiction in either state or federal courts in Colorado or both as appropriate and agrees
that the prevailing party shall be entitled to its attorney fees and costs. No decision, act or
inaction of SKF USA, Inc. shall be construed to be a waiver of any right or remedy, and
pursuit of any state or federal causes shall not be deemed an election or remedies. In the
event of any provision of this License Agreement shall be deemed unenforceable, or void, or
invalid, such provision shall be modified so as to make it valid and enforceable and as so
modified the entire agreement shall remain in full force and effect. This License Agreement
sets forth the entire understanding and agreement between the parties and no written or
oral representative of any kind whatsoever shall in any way modifies or expands the terms of
this agreement. In the event of any conflict or inconsistency between the terms of this
agreement and any Documentation, this agreement shall preempt such documentation to
the extent inconsistent.
SKF Static Motor Analyzer—Baker AWA-IV User Manual iii
Notices

NOTICE
All material associated with this license is copyrighted material.
Federal law provides severe civil and criminal penalties for the
unauthorized reproduction, distribution, or use of copyrighted materials
(Title 17, United States Code). The Federal Bureau of Investigation
investigates allegation of criminal infringement for enforcement. Should
you have any questions concerning this agreement, contact SKF USA
Inc. at 4812 McMurry Avenue, Suite 100, Fort Collins, Colorado 80525.
Telephone [phone]; Fax [phone].
By either opening the software packet or using the program, you
acknowledge that you have read this agreement, understand it, and agree
to be bound by its terms and conditions. You further agree that it is the
complete and exclusive statement of the agreement and supersedes any
proposal, dealings, whether oral or written, and any other communications
relating to the subject matter of this agreement.
Important notice concerning warranty and repairs
The warranty is void if the Baker AWA-IV is shipped without shock absorbing packing
material. If the Baker AWA-IV fails, whether it is under warranty or not, call the SKF electric
motor condition monitoring products service department before returning the unit for repair.
If the unit needs in-house repair, our service staff might direct you to ship the unit to the
authorized service center closest to you. This might save both time and money. When calling
the SKF electric motor test products service department or one of the service centers, please
have the model and serial numbers available. These numbers are located on the rear of the
instrument. If the unit is out of warranty, a purchase order will be required if the unit is
returned for repair.
Service department number: [phone] or toll free at [phone].
Hardware warranty information
All products manufactured by SKF USA, Inc. are warranted against defective materials and
workmanship for a period of one year from the date of delivery to the original purchaser. Any
product that is found to be defective within the warranty period will, at the option of SKF
USA, Inc. be repaired or replaced. This warranty does not apply to products damaged by
improper use. The purchaser shall assume all responsibility and expense for removal,
reinstallation, freight, or on-site service charges in connection with the foregoing remedies.
SKF USA, Inc.’s liability to purchaser relating to the product whether in contract or in part
arising out of warranties, representations, instructions, installations, or defects from an
cause, shall be limited exclusively to correcting the product and under the conditions as
aforesaid.
Virus alert
The Baker AWA-IV contains computer software that is vulnerable to damage from computer
viruses. Before shipping, SKF USA, Inc. scanned all data to ensure the Baker AWA-IV is
iv SKF Static Motor Analyzer—Baker AWA-IV User Manual
Notices

virus-free. Before inserting any disks into the disk drive or connecting the Baker AWA-IV to a
computer network, scan all disks for viruses.
Trademarks
All other trademarks, service marks or registered trademarks appearing in this manual are
the trademarks, service marks or registered trademarks of their respective owners.
SKF Static Motor Analyzer—Baker AWA-IV User Manual v
Notices

Declaration of Conformity
Manufacturer’s Name and Address:
SKF USA, Inc.
4812 McMurry Ave
Fort Collins, CO 80525
USA
Equipment Description: Testers for Surge, DC Hi-Pot, and Winding Resistance of motors.
Equipment Model Designations: AWAIV-2 , AWAIV-4, AWAIV-6, and AWAIV-12.
Application of Council Directive 72/23/EEC 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/EEC 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.
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, SKF USA, Inc. Electric Motor Condition Monitoring
vi SKF Static Motor Analyzer—Baker AWA-IV User Manual
Notices

Table of contents
1 About this manual 1
Formatting ............................................................................................................................ 1
Information devices .............................................................................................................. 1
2 Safety and general operating information 3
Symbols on equipment ........................................................................................................ 3
Labels on equipment ............................................................................................................ 3
Safety precautions ................................................................................................................ 4
Emergency stop button ........................................................................................................ 6
Baker ZTX E-stop and remote E-stop ................................................................................ 7
General operation, maintenance, and service information ............................................. 8
Unpacking the unit ................................................................................................................ 8
Power pack lifting and shipping ......................................................................................... 9
Operating and shipping positions .....................................................................................10
3 Baker AWA-IV instrument overview 11
Baker AWAIV 2kV/4kV model front panel ........................................................................11
AWAIV 6kV/12kV model front panel.................................................................................13
4 Baker AWA-IV software overview 15
Starting the software ........................................................................................................15
Creating a new database ...................................................................................................16
Opening an existing database ...........................................................................................17
The first time version 4 software is used .........................................................................18
Main window ......................................................................................................................19
Main menu ...........................................................................................................................20
Toolbar ..................................................................................................................................24
Ta b s .......................................................................................................................................25
Viewing test data .................................................................................................................29
Using the Data tab ..............................................................................................................30
Data tab—Surge view ........................................................................................................36
Using the Tests tab ..............................................................................................................41
Test configuration ..............................................................................................................42
Manually entered resistance measurements ..................................................................45
Wye-wound resistance measurement .............................................................................45
Delta-wound resistance measurement ...........................................................................45
Coil resistances ....................................................................................................................46

DC Tests: Meg-Ohm/PI/DA/ HiPot/Step or Ramp Voltage test window ......................46
Ramp voltage test ...............................................................................................................47
Step Voltage test window ..................................................................................................48
Surge Test window ..............................................................................................................49
E bar graph ..........................................................................................................................51
Setting up test parameters for a reference waveform ...................................................52
Testing a reference motor ..................................................................................................52
Testing a production motor by comparing with a standard motor ...............................53
Viewing surge results .........................................................................................................54
Using the Trending tab .......................................................................................................55
PI ...........................................................................................................................................58
Hipot .....................................................................................................................................58
Relative humidity ................................................................................................................59
Special software trending features ...................................................................................59
5 Database management and maintenance 61
Database management ......................................................................................................61
Starting the software ........................................................................................................61
Creating a new database ...................................................................................................62
Opening an existing database ...........................................................................................63
Using multiple databases ...................................................................................................64
Data Transfer feature ..........................................................................................................65
Archiving a database .........................................................................................................69
Restoring a database ..........................................................................................................70
Converting an older database ...........................................................................................72
6 Setting up the Baker AWA-IV tester 75
Printer configuration ..........................................................................................................75
Provided memory key ........................................................................................................75
Use of footswitch .................................................................................................................75
7 Test procedures 79
Recommended testing sequence ......................................................................................79
Recommended test voltages – HiPot and Surge tests ...................................................81
Performing an example test ..............................................................................................82
Reviewing test results/data ................................................................................................93
Printing reports ...................................................................................................................96
8 Special features of the Baker AWA-IV 101
Predictive maintenance ................................................................................................... 101
viii SKF Static Motor Analyzer—Baker AWA-IV User Manual
Table of Contents

Quality control .................................................................................................................. 102
Motor troubleshooting .................................................................................................... 102
Field coils ........................................................................................................................... 102
Hi L in Baker AWA-IV 2 kV and Baker AWA-IV 4 kV .................................................... 103
Using the Hi L technique ................................................................................................ 104
Fine tuning the technique ............................................................................................... 105
9 Motor testing theory and reference 111
Coil resistance testing principles and theory ............................................................... 111
Inductance, impedance, and phase angle measurement principles and theory ..... 112
DC testing principles and theory .................................................................................... 120
Surge testing principles and theory............................................................................... 125
Surge testing applications .............................................................................................. 129
10 Typical winding faults 145
Basic wave patterns used to determine faults ............................................................. 145
Application notes .............................................................................................................. 148
Factors affecting tester output ....................................................................................... 149
Software fault messages................................................................................................ 150
Resistance failure types ................................................................................................... 150
DC tests failure types ....................................................................................................... 151
Surge test failure types ................................................................................................... 151
11 Using power packs with 6/12 kV models 153
Power pack set-up ........................................................................................................... 154
Operating position ........................................................................................................... 154
Power pack resistance testing ........................................................................................ 155
Testing with the Baker 30 three-phase test lead power pack .................................... 155
Testing with the Baker 24 single-phase test lead power pack ................................... 158
Addressing Surge test nuisance failures ....................................................................... 160
Combining Baker AWA-IV host and power pack tests ................................................. 161
12 Using the Baker ZTX with Baker AWA-IV testers 169
Principles of armature insulation testing ..................................................................... 169
Connecting Baker AWAIV to the Baker ZTX accessory ................................................ 170
Software settings ............................................................................................................. 170
Configuring a surge test using the Baker ZTX .............................................................. 172
Reviewing test results/data ............................................................................................. 176
Printing reports ................................................................................................................ 178
SKF Static Motor Analyzer—Baker AWA-IV User Manual ix
Table of Contents

Appendix A — Baker AWA-IV troubleshooting 181
Self help and diagnostics ................................................................................................ 181
Repair parts ...................................................................................................................... 181
Step #1: Basic information ............................................................................................ 181
Step #2: Applications or service problem? ................................................................... 182
Applications: What to do first! ......................................................................................... 182
Service: What to do first! ................................................................................................. 184
Open condition display .................................................................................................... 184
Hipot display checks ........................................................................................................ 184
Open ground check .......................................................................................................... 185
Limited output surge waveform ..................................................................................... 185
Proper storage of leads/unit ........................................................................................... 185
Checking test leads for broken sections ........................................................................ 186
Manual break check ......................................................................................................... 186
Overcurrent trip test ........................................................................................................ 186
Open circuit test to verify tester operation ................................................................... 186
Third party software warning ........................................................................................ 187
Baker AWA-IV calibration information .......................................................................... 187
Warranty return ............................................................................................................... 187
Appendix B — Software basics and installation 189
Navigating the software interface .................................................................................. 189
Buttons .............................................................................................................................. 189
Text fields .......................................................................................................................... 189
Scroll bars and Windows® icons ................................................................................... 190
Baker admin or user shell ............................................................................................... 190
Software installation ....................................................................................................... 190
Desktop install .................................................................................................................. 190
Appendix C — Technical specifications and applicable standards 191
Baker AWA-IV 2 kV and 4 kV tester specifications ...................................................... 191
Baker AWA-IV 6 kV, 12 kV, and 12 kV HO tester specifications ................................. 193
Applicable standards ....................................................................................................... 195
Appendix D — Database definition 197
Version 4.0 database definition ..................................................................................... 197
Nameplate table—(MotorID) .......................................................................................... 197
Test results table—(TestResults).................................................................................... 199
Memo table—(Memo) ..................................................................................................... 204
Polarization Index Test Results table—(TestResultsPI) ............................................... 204
x SKF Static Motor Analyzer—Baker AWA-IV User Manual
Table of Contents

Step Voltage test results table—(TestResultsPrgHiPot) .............................................. 206
Test results parameters table—(TestResultsParameters) .......................................... 208
Test ID table—(TestId) ..................................................................................................... 212
Step Voltage test ID table—(TestIdPrgHiPot) ............................................................... 216
Reference Surge waveform table— (RefSrgWaveForm) ............................................ 217
Database Information table—(DatabaseInfo) .............................................................. 218
Work list table—(Route) .................................................................................................. 218
Motor voltage class table—(MotorVoltageClasses) ..................................................... 219
Appendix E — Baker AWA-IV specific winding faults 221
Software fault messages................................................................................................ 221
Resistance failure types ................................................................................................... 221
DC tests failure types ....................................................................................................... 222
Surge test failure types ................................................................................................... 222
Appendix F — Glossary of terms 223
Index 227
SKF Static Motor Analyzer—Baker AWA-IV User Manual xi
Table of Contents

xii SKF Static Motor Analyzer—Baker AWA-IV User Manual
Table of Contents

1 About this manual
This manual uses the following conventions in formatting, and informational devices to help
you more clearly identify specific elements and information.
Formatting
Interface items are set in Initial Caps and Bold.
Page or window names are set in italics.
File names are set in courier font.
Information devices
Information requiring special attention is set in the following format and structure:
NOTE
Indicates additional information about the related topic that deserves closer
attention or provides a tip for using the product.
NOTICE
Indicates information about product usage that can result in difficulty using
product, a loss of data, or minor equipment damage if not heeded.
CAUTION
Indicates a hazardous situation with potential for minor to moderate injury
or property damage, or moderate to severe damage to the product.
WARNING
Indicates a hazardous situation with risk of serious bodily injury or
death.

2 SKF Static Motor Analyzer—Baker AWA-IV User Manual
About this manual

2 Safety and general operating information
Symbols on equipment
Table1 Symbols and labels used on equipment.
Symbol/Label Description
Protective conductor terminal. Located beside black ground
test lead on front panel of instrument.
Frame or chassis terminal. Located on rear panel of
instrument by ground terminal.
Warning about hazardous voltage and risk of injury or death
from severe electrical shock. Located beside each red test
lead on front panel of instrument and on back of unit.
Labels on equipment
The following Danger notice label appears on all four sides of the power pack units used with
the Baker AWA-IV and on the top of the Baker AWA-IV unit itself.
Figure 1. High voltage warning label.

The following safety labels are found on the right side of the power packs:
Figure 2. Power pack lead safety labels.
Safety precautions
Read and follow all safety precautions and safe operating practices in your manual. Do not
exceed maximum operating capabilities of the Baker AWA-IV tester, power packs, or the
Baker ZTX accessory.
The general safety information presented here is for both operating and service personnel.
You will find specific warnings and cautions throughout this manual where they apply.
If using the equipment in any manner not specified by Baker Instrument Company, an SKF
Group Company, 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.
Test related
• Two-party operation is recommended only when using proper equipment (such as
the remote E-Stop) and when taking appropriate precautions so both operators are
aware of all conditions at all times.
• Always know what test is being performed and when. For example, do not adjust
test leads when operating a footswitch. Leads will have live voltage and severe
electrical shock may result.
• For capacitor-started motors or systems with surge arrestors/power factor
capacitors, be sure to disconnect all capacitors from the test circuit before testing.
• Upon completion of any DC-HiPot, megohm, polarization index (PI), step voltage, or
dielectric absorption (DA) tests, be sure to short the winding to ground and allow
time for discharge before disconnecting the test leads. If you do not do this, voltage
may build up on the winding. Industry practices suggest allowing a winding to
discharge four times the total amount of time that DC voltage is applied to the
winding.
• If the tester is removed from the windings before complete discharge, short winding
leads together and ground them using appropriate jumper cables.
• Make sure to disconnect the tester leads before energizing or powering up the
motor.
4 SKF Static Motor Analyzer–Baker AWA-IV User Manual
Safety and general operating information

• 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.
General
• 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 required by your organization, including high-
voltage gloves and eye protection.
• The devices covered in this manual are not waterproof or sealed against water entry.
• The devices covered in this manual are intended for indoor use. If using outdoors,
you must protect the device(s) from rain, snow, and other contaminants.
• Repair parts warning: You must 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 manual 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.
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,
can cause an electric shock!
NOTICE
The ground-fault system on the Baker AWA-IV will render it inoperative
without a proper ground. When the host Baker AWA-IV tester is connected
to a power pack, an inoperable condition will also affect the power pack.
SKF Static Motor Analyzer–Baker AWA-IV User Manual 5
Safety and general operating information

Emergency stop button
The Baker AWA-IV tester and the power packs are equipped with a red Emergency 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 Emergency
Stop button clockwise.
Figure 3. Power pack showing Emergency Stop button.
6 SKF Static Motor Analyzer–Baker AWA-IV User Manual
Safety and general operating information