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1. Aw Eee Tani Vene fV x ad Fe x Life zm Bavi lost Yasha ran faria yaliry cure Core lri V Lake Cons Tan el SEE Comal P Satie O Edie 1 is Fig 3 22 Edit Surge 16 If a dual station machine select station where part being learned is positioned and type 1 or 2 or use the up and down toggle switch to change the station number 17 Highlight or Tab and set voltage compensation to a No compensation b Manual Highlight and type appropriate Voltage increase 18 Highlight tab or toggle AutoTime Base to on or off The system is default set to auto If the surge time base needs to be set identically for each part the auto checkbox can be unlit and the level changed For typical tests the auto check box is usually left checked 19 Click acquire NOTE For a single surge test click on the top level Acquire button to acquire the individual test As a time saving procedure if multiple surge tests are involved for example Main Aux and Reverse click on the second level Acquire button under the All Surge Time Slots to acquire all the surge test waveforms if all limits have been set for each Surge Test The singular Acquire button can be also used to individually acquire each Surge Test separately A surge waveform will appear on the screen for each of the surge tests acquired If multiple surge tests have been acquired the graphical displays will be overlayed over each o
2. LINE with the next digital number refer to 11 Baker WinAST User Manual As with any of the cfg files it is suggested to save work to the C BAKER TEMP directory and lock it for safe keeping Lock the file by using the right mouse button and enter properties ARMLead Default cfg Lines starting with space or are ignored LEAD CFG signals the start of a configuration section No empty or comment lines are allowed within a section CFG COUNT denotes the number of configurations lines to follow No line should exceed 100 characters long Do not change the config names eg 6 LEAD PWS because resistance summation uses them From 12 on are only for the resistance summation not for the surge fsd HHHHHH and it rotation To edit out a config place a space in front of name 6_LEAD_WYE 1 LEAD_CFG 10 BOARD 5_LEAD CFG_COUNT 2 LEAD_CFG BOARD 6 LEAD WYE LINE CFG COUNT 4 5 6 3 LEAD_CFG BOARD 6 LEAD DELTA LINE CFG COUNT 1 6 2 4 3 5 4 LEAD_CFG BOARD 6 LEAD LO SPEED IO LINE CFG COUNT 4 5 6 5 LEAD_CFG BOARD 6 LEAD HI SPEED Baker WinAST User Manual 55 IO_LINE 55 CFG_COUNT 1 1 2 3 6 LEAD_CFG BOARD 0 6 LEAD PWS SEPARATE CFG COUNT 0 17 LEAD CFG BOARD 0 6 LEAD PWS PARALLEL LINE 71 CFG_COUNT 3 1 7 2 8 3 9 8 LEAD_CFG BOARD 0 6 LEAD DBL DELTA LV LINE 78 CFG COUNT 3 1 7 2 8 3 9
3. Baker WinAST Automated Stator Test System User Manual Part No 71102 EN User Manual A Thoroughly read this manual before use of this product Failure to follow the instructions and safety precautions in this manual can result in serious injury damage to the product or incorrect readings Keep this manual in a safe and readily accessible location for future reference Copyright 2013 Baker Instrument Company an SKF Group Company La K Is All rights reserved 4812 McMurry Ave Suite 100 Fort Collins CO 80525 USA Telephone 970 282 1200 Fax 970 282 1010 Customer Service 1 800 752 8272 Baker WinAST User Manual Baker WinAST User Manual SKF USA Condition Monitoring Electric Motor Test Solutions For additional information on products from SKF contact SKF Condition Monitoring Center Fort Collins formerly Baker Instrument Company 4812 McMurry Ave Suite 100 Fort Collins CO 80525 Telephone 1 970 282 1200 FAX 1 970 282 1010 www bakerinst com www skf com SKF is a registered trademark of SKF Group All other trademarks are the property of their respective owners SKF 2013 The contents of this publication are the copyright of the publisher and may not be reproduced even extracts unless prior written permission is granted Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whet
4. Do not create an emergency disk Install most common components next Do not connect to network at this time if no network card is installed Finish setup Finish Remove any disks and restart Windows WINDOWS XP requires you to license your OS You will need a network connection or contact Microsoft to obtain a pass key Restart the computer for all settings to take effect Installation of Baker WinAST software and support programs T Install the Baker WinAST install disk in the CD ROM drive or flash memory Open Windows Explorer 2 Copy the Baker folder from the CD to the C root directory 3 Make the C Baker folder and files writeable by right clicking the Baker folder and select the Properties menu and unchecking the Read only box 4 Open the C BakerlAccessories System32 folder and copy directory to the C winnt System32 windows 2000 or C Iwindows System32 windows XP If asked for Overwrite confirmation select lt Yes for All gt 5 Double Click the C BakerlAccessories SLGRAPH setup exe Finish the rest of its setup using default settings and when prompted for a password type 1342 crhf 4681 6 Click the Start gt Programs gt Command Prompt menu to bring up the Command Prompt window Type the following cd c winnt system32 2000 or cd c windows system32 Baker WinAST User Manual 10 11 Windows XP in the Command Prompt window Then type regsvr32 vef132 0cx in the w
5. Current balance The current balance test is an optional test which checks for reversed coils in certain stators which can not be detected with the other more common tests Usually this problem is detected by the surge test Some winding configurations have coil groups which do not couple in a way that changes the inductance when one of the coils is reversed The current balance test detects these reversed coils In this test a three phase voltage is applied to a three phase stator The current in each phase is compared to the other two phases to verify that the current is balanced within a desired tolerance If the current imbalance is greater than the limit a failure is generated A ME Peer 1 3 DE Ten Rakim L aee U Timm aeri eet mme im ee Fig 3 25 Current balance Resistance summation Resistance Summation is a calculation used when testing three phase stators with more than 3 leads Many companies want to perform a resistance test on individual coils to verify that each coil falls within the pass fail limit But they also want to verify that the phase to phase resistance is correct If a low resistance stator is resistance tested between all leads it is not possible to directly measure the phase to phase resistance at the same time For example a 12 lead dual voltage wye stator usually has 6 resistance tests performed Resistance is measured between leads 1 to 4 2 to 5 3 to 6
6. or 4095 as this condition indicates a fault A generic list of the analog inputs is given below The AIO board generates a 0 5 vdc signal to set the HVDC power supply to requested voltage The area in the upper right is for this purpose with 255 represnting maximum output of the supply The last area on the right is used to control the ACHipot stepper motor which drives the variac Drive the variac up down or reset it back to its zero position Indicated by a check in the digital input box 12 Digital inputs 0 Power 12 ACHipot Variac Zero 1 Keylock 13 Station 1 Stats Reset 2 Supply Status 14 Station 2 Stats Reset 3 Master Enable 15 Station 1 Fail Reset Continuity CO N oa F 11 Station 1 Safety Sw Station 1 Start Station 2 Safety Sw Station 1 Stop Station 2 Start Station 2 Stop Micro Arc Detection Station 2 Fail Reset Continuity DIGITAL OUTPUTS 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Resistance Open Lead HVDC Relay Surge Relay Resistance P S Enable Resistance Scale 0 Resistance Scale 1 HVDC P S Enable Enable Test Lead 1 Enable Test Lead 2 Enable Test Lead 3 Enable Feedback 1 Enable Feedback 2 Enable Feedback 3 Station 1 Testing Station 1 Pass Station 1 Fail TL 4 ROT 1 TL 5 ROT 2 TL 6 ROT 3 FB 4 FB 5 FB 6 Enable Rotation P S Station 2 Testing Station 2 Pass 16 17 18 19 20 21 22 23 48 49 50 51 52 53 54 55 56 5
7. Pl Step Voltage Dielectric Absorption DA or Continuous Ramp Test before disconnecting the test leads short the winding motor etc to ground and allow time for discharge If this is not complete voltage may still be active on leads and tested components 4 Make sure to disconnect the tester leads before energizing or powering up the motor 5 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 6 Use appropriate safety equipment required by your organization including high voltage gloves and eye protection 7 Repair parts warning you must replace defective damaged or broken test leads with factory authorized parts to ensure safe operation and maintain performance specifications 8 Ground the product This product is 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 Danger from loss of ground Upon loss of the protective ground connection all accessible conductive parts including knobs and controls that may appear to be insulated can cause an electric shock 9 This instrument is not waterproof or sealed against water entry 10 The unit is for indoor use If using it outdoors you must protect the unit from rain snow
8. Set Compensation Temperature Set the ambient temperature in one of three ways 1 Ifan IR Probe is available the user can plug it into the port and have the temperature read 2 User Entered From whatever reliable source that in use can enter by hand the temperature 3 Ambient Probe an ambient probe is standard with the Baker WinAST TH as nano Laden Tepti TE LE us laii Es srent Vo Bien Probe Congenzshon T mpsusurs TE Ms Nee F AD Tante M s 228 5 Por CODD bi 2255 alumnum Fil Masse Fig 6 2 Temperature compensation screen NOTE Many of the options listed in the drop down menu are toggle switches Click on the menu item to turn on or off The menu item is considered on when a check mark is displayed in front of the item These items include 1 User Barcode Scanner if available 2 Use Temperature Compensation will use the temperature compensation set up in the programming mode 3 Auto Assign after Editing Master A convenient feature to speed up testing process 4 ACH Compensated Current Enables the AC hipot capacitive compensation current measurement When this is enabled the current displayed during the AC hipot test is resistive leakage current 5 Continue on Fail Testing will continue on part after failure 6 Fail Acknowledge The tester will acknowledge there was a failure before continuing 7 Print Pass Fail Label Enables label Printe
9. 18 uyma m ais I Fan Fee Mygerisem 7 Lern iain Ioa mime ri asp ri Fig 5 2 Main test screen 5 Ifthe part passes the preprogrammed tests the green light on the fixture will light and the software will stop and wait for the next part to be run NOTE Database functionality of the Baker WinAST will not be fully operational until early 2003 Data from everyday operation can be reclaimed within the Baker DB folders under Parts dbf or Results dbf 6 Ifthe part does not pass the preprogrammed tests the red light on the fixture will light The software will display an error message at the top of the screen in blue to inform the user that they must either retest the part or acknowledge the failure To acknowledge the failure press the red failure button on the fixture or click on the green check mark failure acknowledge icon on the screen The instrument is now prepared for the next test Partial Discharge Corona Test Results After a winding test a test result line will appear on the screen for each corona evaluation performed The measured corona value will appear along with the pass fail limit If the measured value is below the pass fail limit the value will be displayed in green If the measured value is above the pass fail limit the value will be displayed in red Se mim TIENS ss m a Tesi Time ETT 1 5374 Crue Ah L 3 1h Stared Humbert CT ee RS EE T Toni aem mm
10. optional or Ground as is appropriate for the process Baker WinAST User Manual Baker WinAST User Manual Figure 3 10 Edit DC hipot NOTE In general all leads are active for DC hipot Edit Rotation Test Parameters 9 Determine Number of Poles Use toggle switch to change NOTE For Reference Only NOTE The number of poles is dependent on the speed of the motor For example a 2 pole motors speed is 3600 rpm at 60 Hz and a 4 pole motors speed is 1800 rpm at 60Hz 10 Determine Phase 1 or 3 Use toggle switch to change 11 Set Test Lead Status For a 1 phase motor and a 3 phase motor all phase leads must be active Example On a three phase motor apply power to the power leads Fig 3 11 Edit rotation test Edit surge test parameters 12 Set Test Voltage using the up or down toggle switch or highlight and type in appropriate voltage 13 Set of Pulses by using the up or down toggle switch or highlight and type in appropriate amount of pulses Fig 3 12 Edit surge 14 If available can decide to use an ARM Configuration The user must understand the part wiring diagram and the ARM Configuration in order for this to work properly Edit current balance test parameters 15 Atthis point in time not parameters are editable for this test Fig 3 13 Edit Current Balance Test Baker WinAST User Manual Baker WinAST User Manual Edit resistance summation Fig 3 14 Edit resistance summation
11. rotation direction etc NOTE Not all test units will have all test options installed Please refer to the service manual for which options are installed on the unit Creation of a new winding group 1 Click on Master select Create Modify Winding Group or click on the Icon L1 on the Screen 2 Click New IL 515 he Fe in Create Parameter List Modify Parameter List Create Master Modify Master Figure 3 2 New Winding Group Assign Master Figure 3 1 Create Modify Winding Group Dropdown 3 A list of all Winding Groups will appear Name the new group with whatever can identify the group most appropriately Baker WinAST 1 15 User Manual Figure 3 3 Winding Group 4 Name or identify each lead with a unique name For example they may correspond to the colors of wire present or the number of the lead in relation to the configuration of the winding Make sure the name chosen corresponds and is distinct to the process being tested For example r b g single for red green blue single phase Figure 3 4 Naming of leads 5 ARM Configuration Auxiliary Relay Matrix If available allows the user to make connections internally to the machine to perform surge and resistance summation Figure 3 5 ARM Configuration a Click Select in the ARM Configuration section of the Screen Baker WinAST User Manual b Highlig
12. use of this software can cause damage to the personnel using it and or to the equipment Baker Instrument Company an SKF Group Company is not to be held responsible for the improper use of this software General The testing screen is divided into several areas The upper section is used for digital inputs such as switch closures power supply status rotation direction etc These are active lows indicated by a check mark in the box A generalized description of each DI line is given below The large center area is a list of the available digital outputs These are user interfaced to turn on relays lamps power supplies etc They can initiate tests on specific leads connect relay matrix isolate trouble areas etc They are also an active low indicated by a mouse click in the adjacent box with a check mark There is a Reset All button at the bottom to reset all lines together Be sure to power down all power supplies before resetting A generic list of the digital outputs is given below The lower area is used to display the Analog values The system uses 0 5 vdc vac analog values from the testing boards to the Baker AIO board in the computer The analog values of voltage and current are converted into digital values to be used by the software for analysis They are values that ride on a noise level that is evident The maximum count is 4095 hexidecimal for 8 bit processor that represents 5 volts or greater input They should never be at hard
13. 0 0 0 45 200 1 Lines SURGE COMP 1 Line58 Coon ll 1 Line59 Cooa y END End of data DO NOT CHANGE THIS LINE END Coumn Baker WinAST User Manual Calibration Check Sheets NOTE This form may be locally reproduced Date Resistance Resistance Range Expected Cobra 5000 Resistance Error Resistance Value Resistance Value Rotation Direction Clockwise Counter clockwise DC hipot Open Circuit Test Cobra 5000 Calibrated Voltage Error Cobra 5000 Leakage Program Value Multimeter Voltage Current uA DC hipot Resistive Load Resistor Value ohms Cobra 5000 Calibrated Voltage Error Cobra 5000 Program Value Multimeter Voltage Leakage Current Value uA AC hipot Open Circuit Test Baker WinAST 1 7 User Manual Cobra 5000 Program Calibrated Multimeter Voltage Error Cobra 5000 Leakage Voltage RMS Voltage RMS Current uA RMS AC hipot Capacitive Load Capacitor Value F x Cobra 5000 Program Calibrated Multimeter Cobra 5000 Leakage Leakage Current Error Value RMS Leakage Current uA Current RMS RMS Surge Open Circuit Test Cobra 5000 Program Cobra 5000 Peak Cobra 5000 Peak Voltage Calibrated Oscilloscope Peak Voltage Error Voltage Peak Voltage 1 8 Baker WinAST User Manual Calibration Certificate SKF certifies that the Baker WinAST serial number
14. 1 mA across the ranges is achieved Check the currents again Ifthe open circuit currents read O consistently raise the AC INTER until reading of 0 1 mA open circuit are achieved across the voltage ranges p Once the open circuit readings are correct attach the appropriate capacitor load between TL1 and Ground NOTE Disconnect any voltmeters and probes from across the load q H Check the leakage at 1000V intervals 7 5mA 3 5ma of leakage current should be present for every 1000V of output If the current does not display 7 5mA 3 5ma per 1000V leakage or too high of an open circuit follow the procedure below If the current is inaccurate by a constant percentage across the range adjust line 24 AC SLOPE in the cal txt file Increasing this number will increase the slope Check the current again If the current reading is inaccurate by a constant amount across the voltage ranges adjust line 25 AC INTER to a lower value until a reading of 7 5mA per 1000V is achieved across the ranges Check the currents again Baker WinAST User Manual 5 The surge test needs to be calibrated in the manual test mode open circuit NOTE Using an oscilloscope and a high voltage probe monitor TL1 with no other load attached Surge test at 1000V 2000V 3000V and 4000V Record the peak reading on the waveform Compute the compensation multiplier needed to achieve the best peak readings across the range For cal txt version 5 and hi
15. COBRASOOO OPTIONS to view the entries NOTE For software builds that do not use a Menu Lockout Key it is necessary to right click the CheckKeyLock name and set the value to 0 NOTE Software after 6 2 03 The ACHipot has a new additional control feature Different frame size stators have a different capacitive compensation phase angle There is now an entry into the Registry Editor to vary the phase angle computation To enter a new value go to lt START gt lt RUN gt and type in lt regedit gt and lt enter gt Locate in the Registry Editor tree the following folder HKEY_CURRENT_USER SOFTWARE COBRA 5000 DEFAULT ACH Locate string value CAP_ANGLE and change string value The lower the value the closer to zero the computed leakage compensation will be The default value will be set to 80 For units with the corona option the CAL txt file must be modified Add 1 00 lt tab gt Line55 lt tab gt Corona below line 54 Add 1 00 lt tab gt Line56 lt tab gt Corona below line 55 ARM configuration file setup for units with an auxiliary relay matrix The new Windows software uses an ARMLead cfg to setup the relay matrix for surge and rotation It also keys the resistance summation routines The file is located in the C Baker directory and is opened in Notepad to edit The header has instructions on modification of this file This file is only to be used in conjunction with the hardware build to produce the desired results The b
16. FB 4 Analog 19 FB 12 Analog 4 DC I Analog 12 FB 5 Analog 20 FB 13 Analog 5 Temp Sta 1 13 FB 6 Analog 21 FB 14 Analog 6 AC V Analog 14 FB 7 Analog 22 FB 15 Analog 7 AC I Analog 15 FB 8 Analog 23 FB 16 Analog Baker 1 3 User Manual Baker WinAST operator self test Under Utilities a selection of Self Test which will run an optional test of the power boards in the sub rack and their communication with the computer boards There is an AC hipot test DC hipot test Resistance range test and a Surge test An operator system will return all green with a green pass light Any faults will be noted in red This will not test the output MUX boards and the fixture for proper operation 1 4 Baker WinAST User Manual Baker WinAST User Manual 12 Test fixture interface Test lead ground connector The Test Lead Connector in the test fixture connector wiring is the wire to the Kelvin contacts on the fixture Test leads and feedback leads must contact the winding independently These leads must be kept as short as possible Model No Pin Number 1 Test Lead 1 2 Feedback Lead 1 for Kelvin Resistance Test 19 Ground Lead 21 Test Lead 2 26 Feedback Lead 2 27 Test Lead 3 31 Feedback Lead 3 Safety Connector The Safety Connector requires relay or switch closure to indicate that the station is ready and safe to test Tests will not start until this closure is made Model Number Pin Number 1 Safety Switch 2 Safety Switch Re
17. Was calibrated on the date below using test instruments and meters with current calibration certificates traceable to the National Institute of Science and Technology NIST The following is a record of the tests which have been made the loads and instruments used for the calibrations and their next calibration due dates The measured calibration check values are recorded Actual values are those measured by the reference test instruments Measured values are those measured by the Baker WinAST The following measurements fall within the calibration tolerances listed in the Technical Specifications SKF Representative Signature Date of Baker WinAST Calibration AC hipot voltage leakage current if installed Leakage Current Method Installed Total or Absolute Leakage Current Method Real or Resistive Leakage Current Method Test Instruments Fluke model 8062A Multimeter Cal Due Fluke model 80K 40 High Voltage Probe Cal Due Open Circuit Test Program Voltage V Actual Voltage V Measured Current mA 1000 2000 3000 3500 Baker WinAST 1 9 User Manual Load Test Calibration Load microfarad capacitor Program Actual Measured Actual Voltage V Voltage V Current mA Current mA 1000 2000 3000 3500 DC hipot voltage and leakage current Test instruments Fluke Model 8062A Multimeter Cal Due Fluke Model 80K 40 High Voltage Probe Cal Due Open circuit test Program Voltage V Actual Voltage V Meas
18. accuracy Pulse Energy 0 5 Joules maximum Discharge Capacitor 0 4 F Load Greater than 100 H Digitizing Rate 5 Msample second Programmable pass fail percentage limit based on Baker Instrument Company an SKF Group Company s patented Error Area Ratio technique Rotation direction optional Senses clockwise or counterclockwise rotation direction in windings Hall Effect Sensor method Single and multi phase options Fixtures The Baker WinAST Automatic Winding Test System can be configured with standard or customized fixturing for the testing of all windings Power requirements Input Voltage 230 V 50Hz 2A 400V 50Hz XA 3 with Rotation test option Power Consumption 500 VA maximum Overcurrent Protection 2 pole magnetic circuit breaker for mains 4 pole magnetic circuit breaker with rotation test option Baker WinAST User Manual Baker WinAST User Manual Physical characteristics Instrument Weight 425 lbs or 192 78 kg Baker WinAST User Manual Appendix B Installation acceptance form Installation Acceptance Form Baker WinAST Automatic Winding Test System Date Customer Contact Purchase Order Invoice Number Serial Number Installation site please record this on the next page This acceptance form is composed of two sections the Installation Check List and Baker WinAST training With a few exceptions two days of installation and training have been paid for For additional assis
19. data files are stored in the c Baker data directory Whenever a new Accounting Period is entered the current data files are backed up and stored with a date and time as part of the file name in the c Baker data archive directory The accounting period can be set up to back up the current files and create new files in time increments of one shift one hour one day one week one month and one year After selecting the time increment select the start time of the time increment The Baker WinAST recognizes that a new accounting period has been entered the first time that it tests a Master within the new accounting period So the most recent data file is always stored in the c Baker data directory until that Master is tested after a new accounting period has been entered Le Hp iC ES Fig 7 3 Calibrate Field calibration The field calibration menu allows the Baker WinAST calibration values to be adjusted easily from the Baker WinAST program without exiting the program and editing the primary cal txt file The field cal coefficients are multipliers which adjust the measured values up or down The field cal coefficient changes the real cal txt coefficient by multiplying it by the field cal value For all but the temperature these values are percentages For example if the Baker WinAST measures winding resistance of a 10 0 ohm resistor to be 10 2 ohms the measured value will be two
20. have high voltage during this test b Step through the voltages at 1000V per step until 5000V is reached Check the voltage If the voltage is more than 5 from the programmed voltage proceed to the Cal txt file Adjust line 6 for the DC hipot voltage Since there is only one cal use the required testing voltage c Check the DC hipot current calibration with and without a load before making any changes Check the hipot leakage open circuit with no meters or probes attached to the test leads The test time should be reduced to 1 second Check the current at 1000V intervals up to 4000V At open circuit the hipot must read zero or near zero on the Baker WinAST before it can be calibrated with a load d Check the leakage current calibration with a load Attach a 100 megohm resistor across TL1 and Ground Disconnect any voltmeters and probes from the load 10uA of leakage current should exist for every 1000V of output NOTE If the current does not show 10uA per 1000V leakage or a high open circuit current follow the procedure below to calibrate the leakage current e Checkthe current open lead with no probes or meters attached Check the current at 1000V intervals up to 4000V If the current is inaccurate by a constant percentage across the range then adjust line 2 SLOPE in the cal txt file Increasing this number will decrease the slope Check the current again f If the current reading is constant across the voltage ranges a
21. hipot arc detection To improve on the RMS current measurement techniques the WinAst 8800 has the ability of detecting both arcs and micro arcs Arc detection enables the tester to detect breakdowns sometimes missed by a capacitance compensated RMS average current measurement technique The WinAst 8800 detects arcs caused by insulation failure resulting in high current The arcs are detected in one of two ways During the initial ramp up of the AC hipot voltage the voltage waveform is continuously sampled If an arc occurs dips or spikes will be detected on the waveform and reported as an arc Once the AC hipot voltage has stabilized the hardware continuously monitors for higher frequency transients in current Any transients in the current are reported as an arc Since the hardware detection circuitry is always monitoring the current arcs are always detected unlike software sampling which may miss micro arcs that occur between samples Micro arcs can be seen in a stator that has an improperly inserted slot liner or a turn that is on the wrong side of the slot liner When this occurs a small micro arc can be seen in the slot between the wire and core These micro arcs differ from normal arcs which affect the average current in that they are not sustained and they are not high current The sensitivity of this circuit is adjustable via a potentiometer on the AC hipot board DC hipot Baker Instrument Company an SKF Group Company
22. is difficult to operate the disconnecting device s Make sure to have 2 5 feet access to the right side of the machine and 2 feet from the rear of the machine Intermittent operation limits At this time there is no intermittent operation limits to use of the DR unit Symbols on equipment Protective conductor terminal Located beside black ground test lead on front panel of instrument H ill Earth ground terminal N Frame or chassis terminal Located on rear panel of instrument by ground terminal Warning about hazardous voltage and risk of severe electrical shock or death Located beside each red test lead on front panel of instrument Other Information Cleaning and decontamination Keep the unit clean and in a dry environment To clean the unit power down and unplug the instrument Wipe with a clean water dampened cloth Do not submerge in water or other cleaners or solvents To clean the screen take a soft water dampened cloth and gently wipe the surface Technical assistance authorized service centers See our website at www bakerinst com for technical assistance authorized service center information This information will be marked with an asterisk Intermittent operation limits At this time there are no intermittent operation limits to the use of the unit Pollution degree II From IEC 61010 1 3 6 6 2 Only non conductive pollution occurs However tempo
23. loss of data Environmental specifications The operational temperature range is zero to forty degrees Celsius This is a totally enclosed non ventilated instrument enclosure is dust tight to IP40 standard and is suitable for most industrial environments Water and dust proof 1055 NEMA 12 enclosures are available as an option Maintenance schedule The lithium battery in the computer should be replaced every five years by a Baker service technician This is not a user serviceable part The filter located on the front panel of the PC Sub Rack should be removed and cleaned at least once a week Wash the filter with warm water and a mild detergent or by blowing the dust free with a compressed air source Fixtures such as test stands may need routine maintenance Test leads and contacts can wear out from normal operation The frequency of component replacement and routine scheduled maintenance will vary among fixtures depending of the amount of use Baker WinAST User Manual Baker WinAST User Manual 10 Calibration Doc title calibration for low voltage Doc No 6 502 001 Rev No A Date 2 16 99 Page 1 of 5 Required tools and equipment 1 Ambient temperature measurement device for degrees Celsius Accuracy 20C 2 Oscilloscope with 100x or 1000x probe optional 3 Volt resistance current meter 4 place measurement Fluke 8062A multimeter 4 HV capacitor for AC hipot cal 5Kv minimum 01 uf for 13
24. mum um n wa Bam i Boa AUN aUa nma Bum ha vee n Ses Maik ams C Biais edens LET Sie mm Fete TI Rem ER CCR Fig 5 3 A typical results screen in which the measured corona value exceeds the limit Using the mouse to click on the View Surge waveform graph will display the digitized corona data The number of corona failures is tallied in the Statistics file which can be displayed on the front screen Corona test values are included in the raw test data stored to the xml results database Manual test This test mode is useful for quickly troubleshooting intermittent or unusual results from general run processes A part can be tested quickly within the manual mode without having to create modify or assign masters 1 Startthe Manual Test in two ways a Click on Test and then on Manual Test b Press F7 This will show the Manual test screen Baker WinAST User Manual Baker WinAST User Manual mm bare tee y me Gi Sij sl ee Wavebes Miles ee en kei ie i a 3j Ber AD Pasare Tar Ted Wig Tani Anka IENH i Tei Foliage Vj m las Tas beii L Lau Vae lec i Heim Pook oni beh me At Poem kasd d CRT LE Bhegas Mewar Hera Conan VIER 2 Eigen T Mano Hame Daher PS NEUTER ees assis um Por pes Daa pou Dep Taaa ROC Cien OOO Fig 5 4 Manual test screen 2 Click on the 2 Lead or 3 Lead radio button a
25. requirements 1 SKF Baker purchased fixtures a Equipment supplied by SKF formerly Baker Instrument Company an SKF Group Company are equipped with the proper connections on the rear of the instrument These connections are labeled with like labeling and must be matched up with each connection cable b Al necessary dry contact closures are present to establish the high voltage output 2 Non SKF purchased fixtures a For fixtures not supplied by SKF the customer must supply a dry contact closure for a safe testing environment b This dry contact closure can be a light curtain pressure mat or to other customer requirements c All Baker WinAST units require this closure to provide the high voltage output Baker WinAST User Manual Baker WinAST User Manual Setup The Baker WinAST software is installed on the Automatic Test System Turn the key on the front of the computer to the unlock position to verify that the computer is on When the computer has completed booting press the green master enable button located on the front of the unit This enables the system for testing Once the instrument has been logged into and the computer finishes booting up to the desktop view double click on the Baker WinAST Icon to start the software The following screen will appear Figure 2 1 Main screen of the Baker WinAST Comprehensive test capabilities The Baker WinAST Automatic Test Systems offers a wide range of tests that all
26. the OPTIONS menu Disconnect any stators or other loads form the fixtures 2 The calibration procedure involves testing the calibration loads and checking output voltages in the MANUAL TEST portion of the Baker WinAST program If adjustments need to be done the calibrator must exit from MANUAL TEST and proceed to the cal txt file in the C Baker config directory The user of this procedure should be familiar with the operation of the including the software and the test lead test fixture configuration Calibration of the Baker WinAST 1 Check the temperature at the Baker WinAST temperature probe 2 degrees is satisfactory against a calibrated temperature probe If the temperature is out of calibration proceed to the Cal txt file Change the calibration number for the TEMP GAIN 5 or ST2 Raising the calibration number will raise the temperature reading while lowering to a smaller number will lower the temperature reading Change this number in very small increments The temperature offset should be left at 273 for solid state sensor and 0 000 for Exergen infrared sensor See notes in parentheses 2 Check the resistance calibration The Baker WinAST is equipped with temperature compensation for resistance and can be turned on or off in the Options menu Turn the compensation off for calibration This test must be done using four wire Kelvin test leads For calibration to be truly accurate measure the calibration resistors with
27. to the left and right and back to the original position A fast analog to digital converter is used to sample and display the surge waveform Typically a Master waveform is learned and stored from one or more known good windings There is typically some variation between good windings due to things such as the magnetic properties of the core the number of turns in the coil or size of the coil When more than one winding is used to learn a Master the Master waveform is averaged When testing subsequent windings the test waveform is compared to the Master waveform Baker has patented a sensitive proprietary method for quantifying the changes in the surge waveform It is called Error Area Ratio The area between the test waveform and the Master waveform is calculated and divided by the total area under the Master waveform The result is a percent error If the two waveforms are identical the difference is zero The greater the differences in frequency or amplitude the greater the error becomes Error Area Ratio Figure 1 3 Example of an error area ratio EAR graph Like the resistance test some difference between the test and Master waveforms is acceptable Many manufacturers allow up to 15 or 20 percent deviation from the Master Sometimes major differences in the materials or process cause the surge waveform to change significantly from the Master It may become necessary to delete and relearn the Master waveform For example the m
28. 16 After all editing has been done click Ok and the software will return to the Create Parameters List screen If all parameters have not been completed an error message will appear Click Ok and the software will return to the test that the parameters have not been edited appropriately Fig 3 15 Error Message 17 Click on Save and Close Parameter List The software will ask for aname for the file Name it something that will be distinct to the process and similar to the name given to the Winding Group file associated with this Parameter List Create a master Each winding model needs it own master file which contains all the configuration information necessary for testing Settings that are configured within the master are leakage limits resistance limits surge master rotation direction etc 1 To create a new Master click on Master and select Create Master or click on the Icon from the screen Fig 3 16 Create Master Dropdown 2 Select the appropriate parameter list by clicking Select and selecting the needed parameter list This will also select the appropriate winding file associated automatically Fig 3 17 Select parameter list Edit resistance test limits Fig 3 18 Edit resistance test limits Set tolerance or resistance according to the process requirements The system is set to default to Tolerance since it is the option most used Baker WinAST User Manual Baker WinAST User Manual 3 Wit
29. 7 58 59 60 61 62 63 64 65 66 67 68 69 70 71 Clockwise Rotation Counter Clockwise Rotation Station 1 Auto Start Station 2 Auto Start Unused Unused Unused Unused TL 13 TL 10 TL 14 TL 11 TL 15 TL 12 FB 13 FB 10 FB 14 FB 11 FB 15 FB 12 Relay Matrix Relay Matrix TL 16 TL 13 TL 17 TL 14 TL 18 TL 15 FB 16 FB 13 FB 17 FB 14 FB 18 FB 15 Relay Matrix Relay Matrix TL 19 TL 16 TL 20 TL 17 TL 21 TL 18 FB 19 FB 20 FB 21 Relay Matrix Relay Matrix Baker WinAST User Manual 24 ACHipot Relay 72 TL 22 TL 19 25 Enable ACHipot P S 73 TL 23 TL 20 26 ACHipot AC Relay 74 TL 24 TL 21 27 ACHipot Variac Step 75 FB 22 28 ACHipot Variac Direction 76 FB 23 29 ACHipot Variac 77 FB 24 30 Station 2 Fail 78 Relay Matrix 31 Motor Pulse Resis Scale 79 Relay Matrix 32 TL 7 TL 4 80 Unused 33 TL 8 TL 5 81 Unused 34 TL 9 TL 6 82 Unused 35 FB 7 FB 4 83 Unused 36 FB 8 FB 5 84 Unused 37 FB 9 FB 6 85 Unused 38 Enable Rotation Sensor 86 Unused 39 Enable Rot Sensor Station SW 87 Unused 40 TL 10 TL 7 ROT 4 88 Unused 41 TL 11 TL 8 ROT 5 89 Unused 42 TL 12 TL 9 ROT 6 90 Unused 43 FB 10 FB 7 91 Unused 44 FB 11 FB 8 92 Unused 45 FB 12 FB 9 93 Unused 46 Station Switch 94 Unused 47 Relay Matrix 95 Unused ANALOG INPUTS 0 Noise Level 8 FB 1 Analog 16 Temp Sta 2 1 Resistance Feedback 9 FB 2 Analog 17 FB 10 Analog 2 Program Output 10 FB 3 Analog 18 FB 11 Analog 3 DC V Analog 11
30. 7 to 10 8 to 11 and 9 to 12 With all 12 leads connected to the Baker WinAST it is not possible to directly measure the high voltage wye connected resistance from leads 1 to 2 2 to 3 as well as 3 to 1 The Baker WinAST resolves this problem by summing the individual resistances to obtain the phase to phase resistance values In the above example the phase to phase resistance between leads 1 and 2 is calculated by summing the resistance measurements of leads 1 to 4 7 to 10 2 to 5 and 8 to 11 A similar summation is performed to obtain the 2 to 3 and 3 to 1 resistance After all three phase to phase resistance values are calculated these can be compared to pass fail limits as well as for resistance balance The resistance summation is tied to the auxiliary relay matrix ARM function The ARM selection denotes the motor winding diagram configuration thereby selecting the resistance summation calculations performed Baker WinAST User Manual Baker WinAST User Manual Fig 3 26 Resistance summation 21 After all limits have been set click save amp close The software will ask for a name for the Master file Usually this is the part number of the winding 22 NOTE Al folder windows contain a skip button which will allow that specific test to be skipped If creating masters off line or prior to a part being available to learn click the skip button to be able to save the created master When parts are available to learn un
31. 9 LEAD_CFG BOARD 0 6 LEAD DBL DELTA HV CFG COUNT 0 10 LEAD_CFG BOARD 0 9 LEAD PWS LINE 54 CFG COUNT 3 4 7 5 8 6 9 11 LEAD_CFG BOARD 0 9 LEAD DBL DELTA HV 1 6 Baker WinAST User Manual IO_LINE 54 CFG_COUNT 3 4 7 5 8 6 9 12 LEAD_CFG BOARD 0 9 LEAD DBL DELTA LV LINE 62 LINE 78 CFG COUNT 3 1 6 2 4 3 5 oN 13 LEAD_CFG I0_BOARD 9_LEAD_DUAL_VOLT_HV IO_LINE 54 CFG_COUNT 3 4 7 5 8 6 9 14 LEAD_CFG 0 BOARD 9 LEAD DUAL VOLT LV LINE 78 IO LINE 54 CFG COUNT 4 1 7 2 8 3 9 4 5 6 15 LEAD_CFG 0 BOARD 0 9 LEAD DUAL VOLT LV DELTA LINE 54 CFG_COUNT 3 4 7 5 8 6 9 16 Baker WinAST User Manual LEAD_CFG 0 BOARD 0 12 LEAD DUAL VOLT LV DELTA IO LINE 62 LINE 78 CFG COUNT 3 1 6 7 2 4 8 3 5 9 17 LEAD_CFG 0 BOARD 0 12 LEAD DUAL VOLT WYE HV LINE 54 LINE 79 CFT COUNT 4 4 7 5 8 6 9 10 11 12 18 LEAD_CFG 0 BOARD 0 12 LEAD DUAL VOLT WYE LV LINE 55 LINE 78 LINE 79 CFG_COUNT 5 17 2 8 3 9 4 5 6 10 11 12 19 LEAD_CFG 0 BOARD 0 12 LEAD DUAL VOLT DELTA HV LINE 47 LINE 54 CFG_COUNT 6 1 12 2 10 3 11 4 7 5 8 6 9 20 1 8 Baker WinAST User Manual LEAD_CFG BOARD 0 12 LEAD DUAL VOLT DELTA LV LINE 62 LINE 78 LINE 47 CFG COUNT 3 1 6 7 12 2 4 8 10 3 5 9 11 Baker WinAST User Manual Ba
32. BUT NOT LIMITED TO IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTABILITY MERCHANTABILITY OF A COMPUTER PROGRAM INFORMATIONAL CONTENT SYSTEM INTEGRATION FITNESS FOR A PARTICULAR PURPOSE AND NON INFRINGEMENT ARE HEREBY DISCLAIMED AND EXCLUDED BY SKF 2 Limitations on liability a Limitations and Exclusions IN NO EVENT WILL SKF BE LIABLE TO LICENSEE FOR ANY DIRECT INDIRECT INCIDENTAL CONSEQUENTIAL PUNITIVE OR OTHER SPECIAL DAMAGES LOST PROFITS OR LOSS OF INFORMATION SUFFERED BY LICENSEE ARISING OUT OF OR RELATED TO THE INSTRUMENT OR THE USE OF THE INSTRUMENT FOR ALL CAUSES OF ACTION OF ANY KIND INCLUDING TORT CONTRACT NEGLIGENCE STRICT LIABILITY BREACH OF WARRANTY OR CONDITION AND STATUTORY EVEN IF SKF HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES THE PRECEDING EXCLUSION AND DISCLAIMER OF DAMAGES SHALL APPLY TO ALL CLAIMS MADE BY LICENSEE RELATED TO OR ARISING OUT OF LICENSEE S USE OF THE PRODUCT Baker WinAST User Manual INCLUDING BUT NOT LIMITED TO CLAIMS ALLEGING THAT THE PRODUCT OR ANY COMPONENT THEREOF FAILED OF ITS ESSENTIAL PURPOSE OR FAILED IN SOME OTHER RESPECT b Acknowledgment The user agrees that the limitations of liability and disclaimers of warranty set forth in this product license will apply regardless of whether SKF has tendered delivery of the product or the User has accepted the product The User acknowledges that SKF has set its prices and granted the licenses contemplate
33. Return of equipment Before returning any equipment or instrument components to Baker Instrument Company an SKF Group Company the following steps should be taken 1 Notify Baker Instrument Company an SKF Group Company at 1 800 752 8272 USA Only or 970 282 1200 Give the representative a full description of the difficulty including troubleshooting steps that may have already been taken Have the model and serial number of the instrument at hand 2 Equipment returned to Baker Instrument Company an SKF Group Company must be packaged in such a manner that it will reach the factory without damage 3 For non warranty repairs Baker will submit a cost estimate for approval prior to shipping the equipment to Baker Instrument Company an SKF Group Company Warning Baker Instrument Company an SKF Group Company assumes no liability for damages consequent to the use or maintenance of this product Refer to the general operating procedures for the Baker WinAST Maintenance and user safety Please read the following before servicing the Baker WinAST 1 Contact with the test leads on this instrument can cause harmful or fatal shock WARNING Never touch the test leads or a winding while a test is in progress 2 Ensure that the Baker WinAST is properly grounded Use a three lead grounded supply or an extra ground lead if unsure of ground supply 3 Ensure that the safety hood is closed on the test fixture and all safety devices are enga
34. a calibrated resistance measurement device Compare the device s reading to the Baker WinAST s reading The calibration resistors supplied by Baker Instrument Company an SKF Group Company are measured with a four wire ohmmeter Set the RES PRECISION to greater than 200 in the Cal txt file for best repeatability B Test the resistance at least once at each range The new version 6 Cal txt has the ability to calibrate at the upper middle and lower area of each resistance range thus insuring better accuracy across the range NOTE If the resistance is out of calibration go to the cal txt file The ranges in the Cal txt are labeled to represent the highest resistance for the range and for the upper and lower calibration points of each range Adjust the calibration number up or down to raise or lower the resistance reading True resistance AST resistance X old cal number NOTE For the 20 kOhm modification the label represents the lowest resistance for the range The last digit in the resistance reading may fluctuate It may take several attempts to calibrate the resistance range 3 a Calibrate the DC high voltage power supply Go to the manual test screen and check DC hipot Set the time to 4 5 seconds and the voltage at 1000v Connect a high voltage probe to the VOM between TL1 and Ground Run the test and check the voltage Baker WinAST User Manual Baker WinAST User Manual WARNING Isolate all other test Leads as they will
35. agnetic properties of a laminated steel core may change the waveform substantially A surge balance test is also available In this case the waveforms from windings within a part are compared to each other rather than to a Master The percent balance error limit is typically less than the absolute limit in comparison to the Master It is typically used by three phase stator manufacturers who check for balance between the phases Principles of partial discharge and corona tests Partial discharge PD also known as corona is a very small electrical discharge caused by the ionization of oxygen in the presence of a high voltage electrical field The ionized oxygen is also known as ozone Ozone reacts with many insulation materials and over a long period of time is corrosive to the insulation causing premature failure in the winding insulation High voltage hipot and impulse testing has long been used to verify the integrity of the ground phase and turn to turn insulation The hipot and surge test were used only to detect catastrophic insulation failure Low voltage motors traditionally did not encounter voltages which generated ozone So testing for the presence of corona at higher than nominal voltage was unnecessary Partial discharge has long been a known failure mode in high voltage motors and generators due to the high operating voltages Motors and generators which initially passed a high voltage breakdown insulation test often still failed q
36. and other contaminants Baker WinAST iii User Manual Preface Declaration of Conformity C Declaration of Conformity Manufacturer s Name amp Address Baker Electrical Instrument Company an SKF Group Company 4812 McMurry Ave Suite 100 Fort Collins CO 80525 USA Equipment description testers for surge DC hipot AC hipot and winding resistance of motor stators Equipment model designation Baker WinAST 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 61000 6 4 EN 61000 3 2 EN 61000 3 3 EN 61000 4 6 hereby declare that the equipment specified above conforms to the above directives and standards Mike Teska Engineering Manager SKF USA Condition Monitoring Center Fort Collins Baker WinAST User Manual Preface Positioning of equipment Positioning of equipment Note Do not position equipment in such a way that it
37. by the mouse The enable corona button must be individually enabled in every surge test Enabling the corona test in one surge test tab does not enable the corona test in all the other surge tests The corona test must be enabled prior to learning the surge waveforms from a known good winding If the user enables the corona test after the surge is learned the learned data must be deleted and relearned wa imam ms eme SU ro TE FL A Fig 3 23 Typical surge corona program screen after programming Note the high frequency corona data in the window below the surge peak When the surge test is learned while the corona test is enabled both the fundamental lower frequency surge waveform will be displayed on the graphs as well as the high frequency corona The corona data is filtered to separate it from the low frequency damped sinusoidal surge waveform The corona data will appear as high frequency noise on the time axis corona is generally most prevalent at the peak applied impulse voltage If corona exists it occurs within a few microseconds of the peak voltage It may also appear at other voltage peaks in the waveform The user can visually see the amount of high frequency corona increase as the test voltage is increased above the CIV The software filter used to separate the high frequency corona data from the fundamental frequency can create some minor high frequency noise in the corona display But a user will
38. ccessfully used to evaluate the condition of the copper conductor in a winding An instrument must be able to resolve the change in copper resistance caused by a short in the winding before conclusions can be made regarding the coil resistance The Resistance Test provides a measure of the tendency of the winding to resist current and convert electrical energy into heat energy Resistance is affected by temperature see above The Baker WinAST Resistance Test compares the percentage difference in resistance between leads with the calculation of Max Delta R Define the acceptable Delta R tolerances for each motor thereby giving the Analyzer pass fail limits The IEEE 118 1978 constant may be selected When the Resistance Test results are displayed by the Baker WinAST measured resistance is listed along with resistance corrected for temperature and the Delta Resistance percentage When Delta Resistance is high a problem with the motor under test may be indicated When the Baker WinAST detects Delta Resistance values not within the prescribed limits the motor fails the test This helps prevent the consequences of high voltage tests on a faulty motor Continuing the test sequence after a test failure is also possible Conducting Resistance Tests on the same motor over a period of time provides early warning signs of motor problems Motors operated in conditions that allow corrosion vibration or other physical damage may show initial warni
39. ccording to the part to be tested NOTE Manual mode works only on 2 Lead and 3 Lead parts 3 Click on the tests that are to be performed and change any parameters as necessary NOTE Tests will be done in the sequence from left to right on the screen 4 start test a Hit green start button on fixture b Click on Test amp click on Start e Click on Icon on screen LN pancer When the test is started above high voltage will be present on the item being tested Do not touch test leads or any connections Electric shock can occur NOTE If the surge test is done the waveforms will appear on the screen This waveform becomes the master waveform In order to clear this waveform click on the New Surge Master NOTE The center line of the surge waveform registered if there is corona present on the part If the line fluctuates and has spikes on it there is corona 5 on In order to exit from the manual test press the F7 key or click on test and click Baker WinAST User Manual Baker WinAST User Manual 6 Options The Options menu contains a number of features presented here m Set Compensation Use srode Scanner Use Temperature Compenaalion w Auto Asagi after Editing Master ACH Comperested Current x Contiram on Foll Fad Acknowledge wf Saved Pesula Database Update Key Lock State Dasa Park C unb er Set Serial Humber LI Auto Stat Fig 6 1 Options Dropdown 1
40. click the test in edit mode 3 Lead Single Phase Stator Baker WinAST User Manual Baker WinAST User Manual Baker WinAST User Manual 4 Modifying the software There may be a number of reasons to modify an existing programming test set For example the company may have another production line that has the same test needs but is under another part number or changes are necessary within the process and the test limits and parameters need to be changed to match the process change For these reasons the Baker WinAST can be easily modified to make the necessary changes in the process Modify an existing winding configuration nn Master Tei Gemera laity He Cr e Paranestes LER Mody Preni LE Bern Fler Fig 4 1 Modify master main dropdown 1 Click on Master select Create Modify Winding Group or click on Icon screen 2 Click box Select which brings up a list box of existing Winding Groups Highlight Winding Group that needs modification and click Open 3 4 Highlight portion that needs modification and make needed changes 5 Click Save amp Close 6 The changes have been made Sais Maur Let PRE jt Pememis Farm Eur Wwednoha Fig 4 2 Select Master List Modify an Existing Parameter List Baker WinAST 1 37 User Manual Fig 4 3 Modify Parameter List Dropdown 1 Click on Master and select Modify Parameter List or click on Icon B s
41. creen The Parameter List window will appear 2 Click on SELECT and select the file name that needs modification 3 All test parameters can be modified in the same fashion as they were when programming See Editing Parameter List 4 Click Save and Close to resave the changes 5 The software will ask if the file needs to be saved under a different name Choose a name that will be easily identified 6 Click OK A second parameters list has now been created Fig 4 4 Modify Parameter List Modifying an Existing Master Baker WinAST User Manual Baker WinAST User Manual Fig 4 5 Modify Existing Master 1 Click on Master and select Modify Master or Icon on screen The Master List window will appear 2 Click on Select and select the filename that needs modification 3 Allthe tests can be modified in the same fashion as they were when programming See Editing Parameter List 4 Click Save and Close to resave the changes 5 The software will ask if it is necessary to save it under a different name Choose a name that will be easily identified 6 Click OK Er Fig 4 6 Select Master List 5 Running tests Running a sample test 1 Click on Master 2 Click on Assign Master Choose one of the three options Station 1 Station 2 both NOTE If the use has a single station machine it will only have Station 1 If a dual station machine is used and is running the same parts on
42. d automatically The second is to store statistical data on a per master basis This information is held by the software even when changing back and forth between masters until a Restart reset counter command is given Although all masters will have the statistical counter reset to zero the prior information is not lost task bar is provided to give the operator a visual indication of the operational count of the Tested Passed and Fail task button is also provided to display a window of the accounting action When the ALL STATISTICS mode is used the task bar window shows the statistics of testing on all parts tested on the unit during the time period chosen A Show Log button will display the storage file of statistical data A Save Log button is to save the information for future use A Restart button will reset the count to zero This information is stored in the C BAKER STATISTICS LOG file When the MASTER STATISTICS mode is used the task bar window shows the statistics of testing on all parts tested using a certain master The master name is displayed for reference A Show Log button will display the storage file of the statistical data for the Assigned master In this mode the button has no use and is grayed out A Restart button is used to save the information for future use and to reset the counter to zero This button will reset all master count information to zero not just the one assigned Th
43. d by Baker Instrument Company an SKF Group Company an SKF Group Company shall be covered only by the express warranty of the manufacturer thereof Baker WinAST User Manual Index A AC Hipot e 28 41 47 54 55 133 AC Hipot Test 28 54 55 Acquire e 49 amplitude e 22 Assign Master e 65 Automatic Test System 9 27 AutoTime 49 C calibration e 99 coil resistance testing e 20 D DC High Potential e 19 dielectric strength e 22 E Editing Test Parameters e 40 Electrical and Calibration Standards e 83 Environmental e 14 E Stop e 29 F Fail Ack e 29 Fail Light e 29 Field Strength Test e 28 Fixture e 29 84 H Hipot e 19 Impulse Surge Test e 28 L LC type 21 lithium batteries e 87 M Master Enable Button 29 master file e 35 45 Max Delta 21 MaxReal 48 Menu Access e 29 misconnections e 21 0 Overcurrent Protection e 87 128 P parameter list e 35 39 45 Pass Light e 29 PC Sub Rack 87 Power Consumption e 87 128 Power Pack e 12 R Rotation Direction e 24 48 97 128 132 133 Rotation Test e 28 S Shipment e 14 Start Button e 29 Storage Indoor Outdoor e 14 Surge e 17 21 28 33 43 49 54 55 57 63 71 75 81 85 87 89 98 101 103 109 113 125 128 129 132 133 135 139 143 surge testing e 21 T Tolerance e 46 V voltage e 20 21 22 28 35 41 43 49 84 87 W winding configuration file e 35 Winding Group e 35 39 45 59 Ba
44. d herein in reliance on the disclaimers of warranty and the limitations and exclusions of liability set forth in this product license and that the same form an essential basis of the bargain between the Parties 3 Term and termination a Term The licenses granted herein shall commence on the user s acceptance of the terms of this product license and shall continue in existence until it is terminated in accordance with Section 3 b below b Termination SKF may terminate this Product license and the license conveyed hereunder in the event that the User breaches any provision term condition or limitation set forth in this Product license including but not limited to the license restrictions set forth in Section 2 b of this Product license c Effect of Termination Within ten 10 days after termination of this Product license and the licenses granted hereunder the User shall return to SKF at the user s expense the Computer Software and all copies thereof and deliver to SKF a certification in a writing signed by an officer of the user that all copies of the Computer Software have been returned to SKF and that the user has complied with the requirements of this Section 3 c 4 Assignment The user may assign this product license in connection with the sale or other transfer of the Instrument provided that the transferee agrees in writing to be bound by the terms of this product license Except as authorized by the pr
45. djust line 3 DCI_INTERCEPT to a lower value until a reading of O 1uA is reached across the ranges Check the currents again If the open circuit currents read O consistently raise the DCI_INTERCEPT until readings are accurate then attach the 100 megohm load between TL1 and Ground NOTE Disconnect any voltmeters and probes from across the load g Check the leakage at 1000V intervals 10uA of leakage current should exist for every 1000V of output If the current does not show 10uA per 1000V leakage follow the procedure below h H If the current is inaccurate by a constant percentage across the range adjust line 4 DC CURRENT SLOPE in the cal txt file Increasing this number will increase the slope Check the current again i If the current reading is inaccurate by a constant amount across the voltage ranges adjust line 5 DC CURRENT INTERCEPT to a lower value until a reading of 10uA per 1000V is achieved across the ranges Check the currents again j Next calibrate the AC hipot power supply Go to the Manual Test screen and check AC hipot Set the time to 8 seconds and the voltage at 1000V Connect a high voltage probe to the VOM between TL1 and Ground Warning Isolate all other leads These leads will have high voltage during the procedure k Check the voltage If the voltage is more than 5 from the programmed voltage proceed to the Cal txt file Type in a new calibration constant and test at another voltage Step through
46. dous situation that if not avoided will result in death or serious injury WARNING This notification indicates a hazardous situation that if not avoided can result in death or serious injury CAUTION This notification indicates a hazardous situation that if not avoided can result in minor or moderate injury NOTICE NOTICE is the preferred signal word to address practices not related to personal injury High Voltage To prevent serious injury or death Do not use in explosive atmospheres Do not contact test leads or the device being testing while a test is in progress or during the discharge period Do not connect test leads to live circuits Read and follow safety precautions and safe operating practices in the operator manual Do not exceed maximum operating capabilities of this instrument Preface Important Safety Information Other Important Safety Warnings Failure to follow these precautions can result in severe electrical shock or death 1 Never attempt a two party operation Always know what test is being performed and when For example do not adjust test leads when operating a footswitch Leads will have live voltage and severe electrical shock may result 2 For capacitor started motors or systems with surge arrestors power factor capacitors be sure to disconnect all capacitors from the test circuit before testing 3 Upon completion of a DC High Potential hipot megohm Polarization Index
47. e a general understanding of the wiring diagram of the part being tested in order to correctly set up the resistance test These leads need to be electrically connected in order to perform the test n Tr Fasern 5 af Res Dj jme cham d uar 8 IL n Fi Figure 3 8 Edit Resistance Test Parameters Edit AC hipot 3 Set Test Voltage appropriately to the part by using the up and down toggles or highlighting and typing the appropriate voltage level Time Slo Test Leads 1 ACTIVE ACTIVE GROUND 2 ACTIVE 3 ACTIVE 4 ACTIVE 5 ACTIVE B ACTIVE OK Cancel Fiaure 3 9 Fdit AC hinnt 4 Set Test Time by Highlighting the box and typing the appropriate time 5 Set Test Lead status by highlighting each test lead and then click on Active Open optional or Ground as is appropriate for the process depending upon build In order to change a lead from ground to active or active to ground highlight the appropriate lead and click either ground or active The lead will automatically change at this point NOTE In general all leads are active for AC hipot Edit DC hipot test parameters 6 Set Ramp Up Voltage by using the up or down toggles or highlighting and typing in the appropriate value ve Set Hold Time by highlighting and typing in an appropriate value 8 Set Test Lead Status by highlighting each test lead and then click on Active Open
48. e and end time of the data included in the calculated partial discharge data The user can thus exclude data which is not likely to be useful PD data Using the learned PD value as a gauge for what might be considered acceptable PD at this test voltage the user can finally enter a pass fail threshold above which the PD will be unacceptable PD by its nature is not perfectly repeatable from test to test So it is likely that a winding will have some PD value variation between tests A user will best learn the PD threshold settings that work for their products through experience in a production environment Some users perform an impulse breakdown test on each winding at a relatively high voltage and perform the corona evaluation as part of that test Using this approach the winding may exhibit significant corona even on a good winding if the breakdown test voltage is above the CIV The user can set a pass fail limit at a level above the acceptable level of corona Most users find it beneficial to conduct a second impulse test for corona at a voltage near the expected CIV This is the preferred test method if the additional test time is tolerable Using this approach the acceptable PD threshold is usually set fairly close to zero How to program the partial discharge test In units with the partial discharge hardware installed the software is configured differently In the surge learn menu there is an enable corona button which can be activated
49. e information is not lost but is stored for future use This information is stored in the C BAKER DB directory It is stored in files using the master name followed by a sts These files will create automatically if not present and will continue to save information as needed The files are a TAB delimited text file and as such can be opened in Xcel These files in both modes can be copied and or deleted New ones will be recreated as needed by the software and operator The statistical data is always on and counting The file size is very small will not slow down testing time The statistical information is also dependent on the operator using the Retest button to produce proper counts of the testing A Retest button will erase the prior test as if it was never run The choice between these modes is made by the correct Registry Editor entry See Software Maintenance in this manual or contact Baker Instrument Company an SKF Group Company Software icons 2008 v3 38 Pe Mew Mie Tet Opiom Ly Hep Sjal m 5 sj mim Be Wi 4 4 2 3 amp 5 67 8 93033 12 18 14 Figure 2 4 Software Icons Top of Screen 1 Close Program 2 Print Results 3 Show Test Statistics 4 Reset all Boards Baker WinAST User Manual Baker WinAST User Manual 5 Fail ACK Ctrl 2 6 Create Modify Winding Group 7 Create Parameter List 8 Modify Parameter List 9 Create Master 10 M
50. e phase power is applied For two phase windings or stators with a main and start winding two phase power is applied Use of a start capacitor when testing a two winding single phase stator is avoided with this method For shaded pole stators single phase power is applied 2 Getting started General information The Baker WinAST Automated Stator Test System is a test system built for production line testing of all types of windings It is designed for use by technicians with minimal knowledge of the Windows operating system The purpose of this manual is to introduce everyday uses of the Baker WinAST It will offer the general workings of the instrument along with programming techniques to help maximize the quality control process Instrument connections 1 This instrument does not require permanent mounting to a floor it is mounted on casters for easy access 2 Use the supplied required power cord Spec 16 3 SJT UL E204241 C CSA LL2126 C FT2 WF If rotation direction is used use the supplied power cord Interpower P N 86020410 cabling Note Customer is required to supply appropriate power disconnect for the rotation direction option 3 New equipment installation requires a Baker Instrument Company an SKF Group Company an SKF Group Company representative to physically install the instrument prior to first operation This is required for safety correct power and operation Interconnection of fixtures and accessories
51. eceding sentence the user shall not assign or otherwise transfer the software or this product license to anyone including any parent subsidiaries affiliated entities or third Parties or as part of the sale of any portion of its business or pursuant to any merger consolidation or reorganization without Baker s SKF s prior written consent Any assignment or transfer effected in violation of this Section 4 shall be void ab initio and of no force or effect 5 General The validity and interpretation of this 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 Product license SKF 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 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 Product license 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 agreemen
52. elect and select Winding Group needed Click Open wm Te heres See nne See Figure 3 6 Creating a Parameter List 3 Add Tests in the order of testing process a To Add Tests click on the test in the Test Board box one at a time and click on Add Test 1 18 Baker WinAST User Manual Baker WinAST User Manual Agia Figure 3 7 Adding Test to Parameter List b The test names can be edited Highlight name of test and it will appear in the small box right below Test Sequence Type whatever is appropriate for the process and press enter after each name change That name will now appear in the Test Sequence box Figure 3 8 Editable Tests NOTE Tests must be named with unique names If two tests are named the same the tester will not operate correctly and testing results could be invalid How to edit test parameters 1 Highlight Test Name in test sequence box and Click Edit Test Parameters A large edit box will appear with window tabs for each test listed on the Test Parameters screen Click on each window tab and edit accordingly All tabs must be edited for it to be accepted If all editing is not done and Error message will appear and take the user to the screen that needs further editing How to edit resistance test parameters 2 Choose which lead will be active and which one the current will return NOTE Attempt to configure leads to correspond with selected test name There needs to b
53. 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 Warning SKF assumes no liability for damages consequent to the use of this product No part of this document content or design may be reproduced in part or in full by any means such as photocopying photographing electronic recording videotaping or facsimile without written permission from SKF Condition Monitoring Center Fort Collins Colorado INTENDED USE OF INSTRUMENT This motor analyzer is offered by SKF Condition Monitoring Center Fort Collins formerly Baker Instrument Company a standard products division of SKF Group This instrument is intended to be used to detect weak or defective insulation within electric motors by industrial motor maintenance or manufacturing professionals who have been trained in its use This instrument is intended to perform only the specified tests that this manual explains in detail Please refer to chapters in this manual concerning specific operations of instrument 1 Limited warranties disclaimer a SKF s sole and exclusive warranties with respect to the Instrument and software are set forth in this user manual b EXCEPT AS SET FORTH IN THIS USER S MANUAL AND TO THE EXTENT PERMITTED BY APPLICABLE LAW ALL EXPRESS AND OR IMPLIED WARRANTIES OR CONDITIONS INCLUDING
54. ged before testing a winding 4 The Baker WinAST is NOT APPROVED for use in an explosive environment 5 Operation of the tester by persons who are using a pacemaker may present unusual safety risks Such persons should take special precautions Safety protection network minimizes electric shock hazard 1 The computer monitors the Safety Switches and begins a test only when the Safety Switches are engaged 2 The Baker WinAST hardware overrides all computer signals and prevents application of high voltage to an unsafe test station 3 Depending on the instrument an EMERGENCY STOP button is mounted on the front panel of the Baker WinAST or on the attached Fixture that interrupts all high voltage power supplies 4 A yellow Testing light mounted on the Baker WinAST FIXTURE control box is illuminated during all test procedures Danger HIGH VOLTAGE TEST EQUIPMENT SHOULD BE HANDLED WITH CAUTION HIGH VOLTAGE TEST PROCEDURES SHOULD BE FOLLOWED Baker WinAST User Manual Baker WinAST User Manual 9 Introduction to general maintenance Maintenance and troubleshooting The Baker WinAST has been designed for maximum long term reliability and has a limited one year warranty against defects in materials and workmanship The Baker WinAST is designed for easy troubleshooting and repair Each system board has built in self test and diagnostic capability The self test enables the boards to conduct tests on internal circuits t
55. gher alter line 39 SURGE COMP and recheck a Start at 1000V and increase the voltage in 1000V intervals Press the F1 button for every 1000V interval and attain a new master waveform so the Baker WinAST will read the voltage of the waveform If the displayed voltage is inaccurate proceed to the calibration screen and retest the surge calibration The formula to correct is requested voltage divided by displayed peak times the old cal number The surge test has 4 ranges 0 1200V 1200 2400V 2400 3600V and 3600 4800V b B Change the peak voltage reading by adjusting the SURGE 1 2 3 or 4 ranges in the cal txt file A higher number will display a higher voltage on the screen Use an oscilloscope if available with at least an x1000 probe connected to TL1 to check the voltage level NOTE When calibration is complete print the file or document the calibration numbers for reference and make a backup in the event of hard drive corruption This is a typical cal txt file Do not add lines to the file or try to type beyond column 80 The computer reads the cal numbers in this file in the order and in the positions shown Calibration will be inaccurate if extra lines are inserted and if the numbers are shifted Column 80 Customer 155 new stator calibration by John White Cal date 09 25 98 NOTE To edit this file Use the Windows editor Field values must be of the correct type integer or float and in range Field values must start in the 1
56. her direct indirect or consequential arising out of the use of the information contained herein SKF reserves the right to alter any part of this publication without prior notice SKF patents include US04768380 US05679900 US05845230 e US05854553 HUS05992237 US06006164 US06199422 e US06202491 US06275781 US06489884 US06513386 e US06633822 US6 789 025 e US6 792 360 US 5 633 811 US 5 870 699 e WO0_03_048714A1 Baker WinAST User Manual 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 Information furnished in this manual by SKF is believed to be accurate and reliable However SKF assumes no responsibility
57. hin the Tolerance radio button options highlight or tab and type the appropriate value for the upper limit 4 Highlight or tab and type the appropriate value for the lower limit 5 Highlight or tab and type the appropriate value for the nominal resistance limit OR 6 Within the resistance radio button options highlight or tab and type the appropriate value for the maximum resistance limit 7 Highlight or tab and type the appropriate value for the minimum resistance limit Resistance balance calculation The Baker WinAST can compare multiple resistance measurements to each other to verify that the resistances are all within a specified percentage tolerance of each other It is often beneficial to check for tighter resistance balance tolerances within a winding than can be maintained with absolute tolerances There are two formula options for the calculation One option calculates the difference between the highest and lowest values The other option calculates the difference between the value most different from the average and the average The option is specified during the initial configuration of the tester If the user wishes to change the formula selection contact Baker for instructions The balance test must be programmed in the last of the resistance menus which will be compared In the example shown the resistance of Res1 4 Res 3 6 and Res 7 10 are checked for balance The last test which will be conduced is the test furthest to
58. ht the needed Lead Configurations and click on Attach If multiple lead configurations are needed click and hold the Ctrl Key to highlight multiple configurations and click Attach c If an unwanted Lead Configuration is attached highlight it and click on Remove 6 Click Save This returns the software to the main Select Winding Group screen NOTE The following list is the ARM Configurations that exist in the software Motor Type Lead Connect Resistance Summation Formula 6 LEAD WYE 6 LEAD DELTA 6 LEAD LO SPEED 6 LEAD HI SPEED 6 LEAD PWS SEPARATE 6 LEAD PWS PARALLEL 6 LEAD DBL DELTA LV 6 LEAD DBL DELTA HV 9 LEAD PWS 9 LEAD DBL DELTA HV L7 L1 L9 L3 L6 L7 L1 L9 L3 L6 9 LEAD DBL DELTA LV IJE E a I br kad bea wats m mj m 9 LEAD DUAL V OLT HV 9 LEAD DUAL VOLT LV Baker WinAST 1 17 User Manual 9 LEA D DUAL VOLT HV DELTA 9 LEAD DUAL VOLT LV DELTA 12 LEA D DUAL VOLT WYE HV 12 LEAD DUAL VOLT WYE LV 12LEAD DUAL V OLT DELTA HV JE 1 b G t r I I n 12 LEAD DUAL VOLT DELTA LV 11 12 BIBIBIE ofr Creation of a parameter list NOTE A Winding Group must be configured prior to creating the parameter list If this has not been done see Creating a Winding Group 1 Click on Master select Create Parameter List or click on the short cut E on the tool bar 2 Click on S
59. i il i at i 1 i de LESS y T 8 Baker WinAST 1 3 User Manual Baker WinAST User Manual Appendix D Warranty Warranty SKF USA formerly Baker Instrument Company an SKF Group Company warrants title to this product and also warrants product on date of delivery to purchaser to be of the kind and quality described above 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 from date of shipment by company of any item of the product purchaser discovers that such item was not as warranted and promptly notifies company 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 company hereunder Company s liability to purchaser relating to the product whether in contract 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 items of the product such as tubes which is not manufacture
60. ify that the ground is attached when Capacitive Compensation is active 13 The Test Voltage is given for reference but is set in the Parameter file AC hipot partial discharge 14 Hardware set not available as a software control at this time DC hipot 15 Select Max and type the appropriate micro amp value Baker WinAST User Manual Baker WinAST User Manual Fig 3 20 Edit DC hipot Rotation direction 18 Click on the radio button that is appropriate for the application Either clockwise or counter clockwise Ifthe unit is dual station be sure to choose the correct Station for learning the part 19 Click on acquire This will take a look at the connected part and acquire the rotation If the machine acquires the rotation it will state Rotation Acquired Successfully in the grey box The machine at this point has learned the rotation of the part and will look at all other parts to see if the rotation is the same NOTE It is important to make sure that the part that is being used has been check out and is verified to which direction rotation is and that the part is good The Baker WinAST will administer pass fail criteria on all other parts from the information gathered from this part Fig 3 21 Edit rotation direction Surge pee Tien Feiner ipod 9 Se 5 aee Amann Seat T T We Lear Lan Haas T 3 Cul rj deb Coes F Us dei Tasas i ui ME m qur Le Er 4
61. ill apply rotation power during Rotation Test 3 Phase 10 11 amp 12 are used for Test 4 if needed When complete close the folder by clicking the close folder button at the upper right corner Select save to save the entries made to the SysconfigO cfg file It is necessary to lock this file by right clicking the file Sysconfig cfg and selecting Read Only 6 Complete the programming by copying the Oconfig cfg and the SysconfigO cfg files to the C Baker Temp directory Baker WinAST 1 3 User Manual 10 If any problems are encountered following this routine contact Baker at CMC Fort Collins an SKF Group Company for assistance at 1 800 752 8272 Baker heartily encourages the customer to limit the personnel allowed to access this procedure as an improper set up can render the WINAST unit unuseable and possibly could damage the unit Launch the WINAST icon to start the program You will notice a quick shut down normal for first time Launch again and you will notice an incomplete screen Set up a default master for a resistance test from lead 1 to 2 Assign this master and the screen will be complete Open the Show Debug Messages icon and drop down the HELP menu Select Create Regedit Defaults This will set the most common default settings in the registry editor This can be verified by selecting lt Start gt lt Run gt and typing REGEDIT in the selection box This will give a REGEDIT string Select HKEY_CURRENT_USER SOFTWARE
62. ils inductance There are other factors influencing the wave pattern but inductance is the primary one The coil becomes one of two elements in what is known as a tank circuit a LC type circuit made up of the coils inductance L and the surge tester s internal capacitance C Inductance L of a coil is basically set by the number of turns in a winding and the type of iron core it rests in The frequency of the wave pattern is determined by the formula This formula implies that when the inductance decreases the frequency will increase 1 27 LC A surge test can detect a fault between turns that is due to weak insulation If the voltage potential is greater than the dielectric strength of the turn insulation one or more turns may be shorted out of the circuit In effect the number of turns in the coil is reduced Fewer working turns reduce the inductance of the coil and increased the frequency of the ringing pattern from the surge Frequency Baker WinAST User Manual Baker WinAST User Manual The voltage or amplitude of the surge wave pattern is also reduced due to the decrease in inductance of a coil with a fault between turns It is determined by the formula Voltage L a dt Where the current i varies according to pulse time t When the insulation between turns is weak the result is a low energy arc over and a change in inductance When this happens the wave pattern becomes unstable it may shift rapidly
63. inAST User Manual Principles of coil resistance testing The coil resistance test is a very simple test to perform and is an immediate indication of the health of the conductor s in a winding The coil resistance test consists of injecting a known constant current through the winding measuring the voltage drop across the winding and calculating the coil resistance using Ohm s law If a coil is shorted somewhere in the interior of the winding the resistance will be lower than normal This lower coil resistance can be compared to previous measurements of the same coil compared measurements of identical coils or compared to the motor name plate value to identify a bad coil The measured resistance is affected by the variation of copper conductivity with temperature Therefore the measured resistance value should be corrected to a common temperature usually 250C before comparing two different measurements Since the windings found in many motors have very low resistances the injected current might have to be as high as 2 amps to accurately measure the voltage drop across the coil One of the difficulties encountered measuring the voltage drop across the coil itself is the affect of the contact resistance of the clip leads and external relays used to connect to the motor s winding Contact resistances can be comparable or even greater than the resistance of some coils There is a practical lower limit to the coil resistance that can be su
64. indow and lt enter gt A dialog should come up with message DLLRegisterServer in vcf132 0cx succeeded Run the Acrobat reader setup program in C Baker Accessories Acrobat Copy the C Baker Ast exe file to the desktop to provide a shortcut to the WINAST program Right click the icon and select properties Edit the target to c Bakerlast exe debug Create a MANTEST icon on the desktop by creating a shortcut to the C Baker Mantest exe Change the Windows desktop wallpaper to C BAKER LogoBaker2 bmp by right clicking the desktop and selecting Properties Background Wallpaper Locate bmp by using Browse button Also choose Baker Blue for background Restart Windows again to have changes made selectable Baker WinAST Windows driver installation 1 The WINAST unit has SKF Baker CMC computer boards used to control and analyze the tests These boards need to communicate with the WINAST software The drivers for these boards need to be loaded Select the Start Control Panel gt Add Hardware Launch the Hardware Wizard Next choose Yes have already connected the hardware option Select Next Select Add new hardware device Choose the Install the hardware that manually select from a list option Select show all devices After some computer time choose the Have disk option and choose the Browse button Locate the Aio 0x318 inf file in the C BakerlDrivers folder Open it and select OK Select AIO 0x318 from the list and
65. ker WinAST User Manual Appendix A Technical specifications Baker WinAST Automated Stator Test System Computer Processor Pentium Architecture Industrial PC packaging Peripherals Display High resolution LCD color monitor Printer Optional Communications Network interfaces are available DC hipot Voltage Programmable 100 to 5000 VDC in 50 VDC increments 3 percent accuracy Current 100 uA maximum 1 uA resolution programmable pass fail limit in 1 uA increments 1 uA accuracy Duration Programmable in 1 second increments AC hipot Voltage Programmable 100 to 3500 VAC in 50 VAC increments 50 60 Hz 60 VA or 300 VA 5 percent accuracy Current 5 13 26 40 100 mA 0 1 mA or 0 5 mA resolution arc detection for improved fault detection 5 percent accuracy Duration Programmable in one second increments Leakage Current Method installed Total or Absolute Leakage Current Resistance Autoranging 3 5 digit resolution 0 4 of full scale accuracy in each range 0 2 of full scale repeatability Kelvin leads and contacts Ambient temperature normally compensated to 250C or user defined Infrared temperature sensing Optional Resistance Range Current 2 milliohm 200 milliohm 2A 200 milliohm 2 ohm 200 mA 2 ohm 20 ohm 20 mA 20 ohm 2 Kohm 2mA 2 Kohm 20 Kohm 2 mA optional High voltage impulse surge Voltage Programmable 500 to 5000 volts peak in 50 volt increments 3 percent
66. ker WinAST User Manual System Schematics Baker WinAST 1 3 User Manual
67. ker WinAST software was updated during installation a New Software was backed up on customer and Baker service disks b New software was stored on software engineer s customer directory Denotes optional feature Baker WinAST training 1 The installer explained the basics of operating the Baker WinAST 2 The training was satisfactory on the following tests AC Hipot Rotation Direction DC Hipot Surge Test Resistance Test 3 The training was satisfactory on the following test fixture 4 The software training was satisfactory 5 lf applicable the installer discussed the Spare Parts Kit For the installer Please note any comments regarding this installation For the customer Please note any comments regarding this installation Use the back of this form if necessary This installation of Baker WinAST Serial Number Was completed Date by Baker Instrument Company an SKF Group Company Representative Customer Signature 1 4 Baker WinAST User Manual Appendix C Inductance test The Baker WinAST inductance test The inductance test is an optional feature of the Windows 7 based Baker WinAST and is available along with the conventional tests AC hipot DC hipot resistance surge rotation and flux mapping using the same test leads from the Baker WinAST unit It serves as yet another means of electrically testing motor insulation for weaknesses and faults in a motor manufacturing or repair quality assurance prog
68. mA hipots and 02 uf for 40 mA Hipots and 06 for 400 ma TATS 5 100 megohm resistor 200 watts minimum 6 Resistors of known value at least one for each resistance range 2 watt minimum Ranges 1 000 002 TATS only 2 002 02 ohms not used with the 20 000 ohm option 3 02 2 ohms 4 2 2 0 ohms 5 20 20 ohms 6 20 200 ohms 7 200 2000 ohms TATS excluded 8 2000 20 000 ohms optional This procedure uses the Cal txt file in the C Baker config directory for calibration To access this file close the operating program and launch Windows Explorer It may help to create a desktop icon shortcut Edit the appropriate fields in the file To return to the WInAST program click the close button upper right and save the changes Launch the WinAST desktop icon to reenter the testing program NOTE Several versions of the Cal txt file exist line 1 of cal txt contains the version For Cal txt version 4 and higher lines 36 37 and 38 exist for faster Pentium processors These are configured for a specific speed of CPU processor and should not be changed see cal txt notes in brackets There are also additional lines of calibration numbers not discussed in this procedure DO NOT CHANGE THEM NOTE The calibration is usually performed in this order Temperature Resistance DC hipot AC hipot and Surge with the fixture connected 1 To set up the Baker WinAST for calibration turn off all of the options in
69. mal operating conditions In other instances impulse generators or hipot testers are used to apply a high voltage signal to the winding External analog or digital detection circuits are traditionally used to quantify the amount of partial discharge over a relatively long period of time The detection circuits use either voltage or current transducers directly connected to the winding leads or some sort of antenna which captures the radiated energy Baker WinAST User Manual Baker WinAST User Manual Smaller motor manufacturers often find it difficult to use the technology developed for the maintenance industry Motor manufacturers usually need to test low voltage motors in a higher volume production environment Usually the tests are performed by lower skill employees It is important to fixture the test hardware in such a way that the motors are tested quickly and easily It is also important that the test data is quickly and repeat ably converted into a pass fail result Principles of rotation direction testing The rotation direction test is used to sense the rotational direction of the magnetic fields in a winding It uses a hall effect probe placed near the stator bore Power is applied to the windings and the magnetic fields rotate either clockwise or counter clockwise The sensor then detects the direction of rotation Phase power is normally stepped down to approximately 90 VAC and applied to the winding For three phase stators thre
70. med by selecting discrete digital outputs that are determined by the Baker WinAST s configuration and stator testing design 1 2 Baker WinAST User Manual Meis j a or ae Een Maissa AC hipa Serge Fone Era cama 5 El Puer ir Tara Taci FT x Fia E FH auras fe Fax T o3 ga fara re m ux ur i Pet T 3 zx 1 pins M A MERE fra 38 RE ee de SE 55 5 FaFa papa de ea Pal Pal a mapshsaPs Fa Fs Been 1 a 41 5 Pal s ha Pal Pal 5 ma P s Peu Ta wa eee xrxmupg js 3 Ku RU 8 Fs Bs Ps 33 3 hs Bara 5 38 sa mE ma P3 ea a fal 231 Fa I dee den je LEE ES t by ael BS jen ten T bij 51 1145 ll il el 3 kei al Gates Fed Capa Fine huis di wr Dai um Serge Da ARD Le 4M Date cms A 3943 A Appi Sm 45 ag The lead map for a typical Baker WinAST unit is shown above A block diagram of the Baker WinAST multiplexing system is also shown below The lead map is used to assign the proper leads for tests when they are set up in the parameter file The analog number is important to the inductance as it helps to program the inductance multiplex board for proper lead assignment I B c I D I E I F I Ss I E ISE 1 queer D LME lll T ahd a Int ES fo uh
71. n capability to detect intermittent faults which may not be measured otherwise AC hipot The AC hipot test is the standard test used by almost all winding manufacturers in a production environment The AC hipot test is preferred because of its faster test time and it is specified in UL CSA NEMA and other test procedures A high voltage 50 or 60 Hz AC signal is applied to a winding The core and or other windings are grounded The leakage current between the high voltage winding and ground is measure in RMS current The equivalent circuit of an insulation system is a very large resistor the insulation resistance in parallel with a capacitor the capacitive coupling between the two conductors The insulation resistance is very large compared to the capacitive impedance so almost all of the leakage current is capacitive The voltage and current waveforms are almost ninety degrees out of phase The real or resistive leakage current is measured in micro amps The capacitive leakage current is measured in milliamps Some test specs call for a Capacitive Compensation capability when measuring leakage current The goal is to measure the real or resistive leakage current This is very difficult to be accurate and maintain short test times since the capacitive leakage is an order of magnitude greater than the resistive leakage The test specifications take this into account and therefore have relatively large compensated leakage current limits AC
72. ng signs of failure through the Resistance Test Principles of surge testing Prior to the introduction of surge testing the most common electrical test for motors was a low potential test of the winding insulation to ground or frame This popular test is the Insulation Resistance or Meg Ohm test This test is adequate for testing winding insulation to ground but it does not detect failures between turns or phases A more thorough test is the Surge Test A typical motor coil consists of copper wire turns or windings Motor winding insulation failure often starts as a turn to turn copper to copper or winding to winding fault Surge Tests can detect the early stages of insulation failures in the winding such as a coil to coil failures short circuits grounds misconnections and wrong turn counts without permanently damaging the winding Brief voltage surges or pulses are applied to the coil during a Surge Test to create a voltage gradient or potential across the length of the wire in the winding This gradient produces a momentary voltage stress between turns The coil will respond in the time periods between pulses with a ringing or damped sinusoidal waveform pattern Each coil has its own unique signature ringing or wave pattern which can be displayed on the screen In Figure 1 2 Example of a ringing wave pattern resulting from Surge Testing The wave pattern observed during a Surge Test is directly related to the co
73. o verify that they are functioning properly Failure of the self test is indicated by the Error Message window in the Baker WinAST software Basic operation The Baker WinAST consists of a computer and several test circuit boards in a rack mounted configuration There are normally four different test signal sources Resistance measurement board for winding resistance tests High voltage DC power supply for DC hipot tests High voltage DC Stack for surge tests 5 0 TX High voltage AC power supply for AC hipot tests Test signals are routed to the test winding through a test bus Any of the test signal sources can be switched onto the test bus through high voltage relays located on the various boards Only one source at a time can be routed onto the bus The test bus can be connected to any combination of test leads through high voltage relays on the Test Lead Multiplexer TL MUX board Each TL MUX board is capable of switching three test leads Power Requirements Input Voltage 230V 50Hz 2A Power consumption 500VA Maximum Over current protection two pole magnetic circuit breaker Protection Line surge withstands 1 2 50 microsecond 6000 volt 3000 ampere impulse without damage or loss of data Meets IEEE 587 Category B and IEC 664 Category IV standards Electrostatic Discharge Withstands 25 kV 15 ampere 80 milli joule discharge to any point on the instrument enclosure terminal or test leads without damage or
74. odify Master 11 Assign Both Stations 12 Display Station 1 Winding Group 13 Start Test 14 Repeatedly Run Test F key designation F1 Assign Master Station 1 F2 Assign Master Station 2 F3 Assign Master Stations 1 amp 2 F4 Set Serial Number Station 1 F5 Set Serial Number Station 2 F7 Manual Test Baker WinAST User Manual 3 Programming the software Before performing any tests on windings or stators the system must be configured to the process specifications This process involves three steps 1 creating or assigning winding group s 2 creating a parameter list 3 and creating a master The winding configuration file group s contains information about the leads on the winding to correctly map them to the tester s leads NOTE Atleast one winding configuration file group s is needed in order to perform tests The parameter list contains the test parameters for each family of product along with the order in which they will be executed It contains test specific data rather than pass fail limits for a specific winding This gives the ability to change one parameter such as test voltage that applies to a family of windings rather than changing the parameter for each individual winding Each winding type needs its own master file which contains all configuration information necessary for testing These are winding type specific settings such as leakage current limits resistance limits surge master
75. one line choose both This will allow the user to access both fixtures for the line If the user has a dual station machine but is running different parts on different lines the user will want to assign the stations according to the line that are running 3 Load parts into fixture and attach appropriate leads Close fixture safety hood 4 Start Test in one of the following three ways Options Utity Help station Manual Test Mode F7 Station 2 Fig 5 1 Test Dropdown a Click on Test and then click Start Station 1 or Station 2 b Click on Icon on Screen C Press the green or start button on the fixture d Within the Options menu on the software select the Baker WinAST to AutoStart the test The test will begin as soon as the hood on the fixture registers closed and will continue this way until AutoStart is removed LN pancer TN When the test is started above high voltage will be present on the item being tested Do not touch test leads or any connections Electric shock can occur NOTE The instrument will follow the preprogrammed test schedule that was set up in the parameters for the given master As the test is being done the yellow or testing light on the fixture will be lit As the tests are completed they will display the results on the screen Baker WinAST User Manual Baker WinAST User Manual LE ERIT uw Am T HN sis al i Tam Tama us IRL Iren 45 Pemi PE Pain
76. ow a comprehensive look at motor and process quality These tests include AC amp DC hipot tests This test measures the integrity of the winding in relation to ground Resistance test The resistance test measures the resistance between two leads Impulse surge test The high voltage impulse or surge test checks for insulation weakness between turns layers coils and phases of a winding Surge testing also detects other faults that change the inductance or losses in a winding such as reversed coils and improperly annealed steel Partial discharge corona test Partial Discharge PD also known as corona is a very small electrical discharge caused by the ionization of oxygen in the presence of a high voltage electrical field The ionized oxygen is also known as ozone Ozone reacts with many insulation materials and over a long period of time is corrosive to the insulation causing premature failure in the winding insulation Field strength test optional The Field Strength Test determines the magnetic flux per slot in a winding Rotation test optional The Rotation Test determines whether the winding is wound in the proper orientation Operational controls Baker WinAST User Manual Baker WinAST User Manual Figure 2 2 Baker WinAST 1 Control panel e Pass Light Green light that will light when a test has passed e Fail Light Red light that will light when a test has failed e Testing Yellow ligh
77. percent over Adjust the 20 ohm field calibration coefficient to 0 98 and the Baker WinAST will subsequently measure all resistances between 2 and 20 ohms as 2 percent lower The temperature field cal coefficient is not a percentage so the user may need to adjust this coefficient using a trial and error process For a major or complete calibration the user should adjust the calibration coefficients in the cal txt file Only qualified technicians should attempt to adjust the cal txt file Baker WinAST User Manual AS Heo per P Fig 7 4 Test Statistics Test statistics The Show Test Statistics menu displays a table on the front screen with total parts tested parts passed and parts failed In addition the failure tally for each type of failure is quantified In the options menu there is a option to reset this table Fig 7 5 Self test Baker WinAST 1 3 User Manual Self test The self test utility operates the AC hipot DC hipot resistance and surge power supplies of the Baker WinAST All power supplies are used to energize internal loads during the Self Test No power is supplied to the test leads Measured values are displayed on the screen as each power supply is energized The measured values are compared to expected values Values which fall within tolerance are displayed in green Values which fall outside of tolerance are displayed in red Run the Self Test any time there is a suspected hardware problem
78. quickly learn how real corona appears different from this type of noise A time window allows the user to select only the portion of the corona data which he believes to be valid corona data After the surge test is learned the Start time and End time of the window used in the corona evaluation are both zero micro seconds So the calculated corona value is zero pico Coulombs The mouse is used to create a time window for the corona evaluation In the learn surge menu create a box around the corona data to be included in the evaluation The Start time and End time will change accordingly A corona value which is calculated from the Sum of the Delta Ys in the corona window is displayed After creating a window around the PD data on the surge graph select the Zoom on the graph to enlarge the PD data In the Zoomed graph create a new window and select calculate corona again to fine tune the start and end time Baker WinAST User Manual Baker WinAST User Manual The user can use this information as a guide to what might be considered an acceptable level of corona in a good winding The user then enters a corona threshold limit above which the corona test will fail bibra ent Homme ei ei E 3 4 pirs mapp h m Fig 3 24 The PD data displayed after using the Zoom button to fine tune the start and end time of the window When finished adjusting the surge and corona screen save and exit the learn surge menu
79. ram des The measure of inductance in mH is accomplished by incorporating a laboratory quality LCR meter Four wire measurement leads are multiplexed through the Baker WinAST hardware to enable a four wire measurement at the leads of the coil under test This approach allows very low inductances in the range of 5 uH to be measured Communication with the LCR meter is performed via a dynamic COM port assignment of an RS232 cable using the Baker WinAST s software application The Baker WinAST inductance test is capable of testing on 2 through 12 leads of a customer s stator The Baker WinAST s Windows 7 based application is designed to be user friendly Setup of a master test is very similar to the resistance setup using a lead map with the value displayed in mH A balance test similar to the resistance balance test is provided Test results are included in the standard output format of the Baker WinAST Both statistical and total data are stored in xml format Baker WinAST User Manual OT Reberre 574 gj l 5 T al m dim mio W Time 4 sl CH DCH Res 1 Ras 15 Res 28 RES e et OLET nip 25 ee ea Le Tam Marne Ari Tani Pg papa Fara 1 4 Kit Len Pura 2 5 BT E WYE Maser Nene Coke LEAD TEST maa An inductance multiplexer board performs multiplexing of the four inductance meter wires out to the proper lead
80. rary conductivity caused by condensation is expected Baker WinAST User Manual Preface Other Information Baker WinAST User Manual Power requirements Using the provided AC power cord connect the unit to a grounded AC power source The units power requirements are 100 240 V AC 50 60 Hz 2 amps AC maximum current draw An auto reset circuit breaker protects the unit Environmental conditions e The unit has been tested for use up to 2 000 m 6 500 ft e Only operate the tester in temperatures ranging from 5 to 40 C 41 to 104 F e This unit is for use at a maximum relative humidity of 80 for temperatures up to 31 C 66 F decreasing linearly to 50 relative humidity at 40 C 104 F This unit is intended for Installation Category in a Pollution Degree environment Baker WinAST User Manual 1 Principles of high potential hipot testing The hipot test is considered the mainstay of motor testing The purpose of a hipot test is to verify the quality of the insulation between two conductors The most common hipot test is conducted between a winding and a core But it can also be used to test the insulation between two separate windings as is the case with some two speed motors for example hipot tests can be performed using either AC or DC high voltage In both cases the leakage current is measured in order to verify that it does not exceed a set limit hipot testers typically also have arc detectio
81. rranties representations instructions installations or defects from any cause shall be limited exclusively to correcting the product and under the conditions as aforesaid If the unit fails whether it is under warranty or not call the SKF 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 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 phone number 970 282 1200 or toll free at 800 752 8272 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 Table of Contents TOC 2 Preface Important Safety Information Declaration of Conformity Positioning of equipment Intermittent operation limits Other Information ettet Principles of high potential hipot testing AC hipot AC hipot arc detection DC hipot Principles of coil resistance testing Principles of surge testing Principles of partial discharge and corona
82. rs optional equipment 8 Save Results to Database Automatically saves testing results to database 9 Update Key Lock State Baker WinASTs are equipped with a physical lock and key to disable menu access so that operators cannot change master limits and parameters Selecting this menu item updates the menu access based on the key Switch 10 Reset Parts Counter Will reset parts counter to zero 11 SetSerial Number Will increment serial numbers to next number available if checked Will log this information into the database Baker WinAST User Manual Fig 6 3 Set serial number screen 12 Auto Start When toggled to the on position will automatically start tests once the fixture lid is in the closed locked position Baker WinAST 1 3 User Manual Baker WinAST User Manual 7 Utilities How to use utilities Fig 7 1 Utility drop down The Utilities menu has functions which are used to configure the Accounting Period for storing raw test data to show a Pass Fail statistics table on the front screen to calibrate the Baker WinAST and to perform a self test of the power supplies on internal loads Fig 7 2 Set accounting period Accounting period The Accounting Period is used to organize the stored raw test data xml files Raw test data is stored to files in attributed xml format These files are backed up and a new file is created periodically as specified by the selected Accounting Period The current
83. s The board is controlled by a dynamic COM port assignment RS232 cable and the analyzer s software The analog signals are isolated from the Baker WinAST s computer boards They are read by the analyzer s inductance meter and captured by the analyzer s software via RS232 protocol The following is a technical report of how the Baker WinAST is designed to measure 4 wire inductance through multiplexed leads The L force inductance force output of the inductance capacitance resistance LCR meter is protected by being routed through a high voltage isolation relay to the Baker WInAST test bus The return H force is connected to the high voltage return L sense and H sense leads are connected to feedback leads of the test cable to the requested coil leads This senses the analog signals to the LCR meter from the test lead multiplex boards the Baker WinAST backplane board and the inductance multiplex board Coaxial cables in the system reduce noise interference The Baker WinAST application software sends controls via RS232 protocol to the inductance multiplex board to properly route the analog signals A troubleshooting software program along with the standard mantest exe is included with the Baker WinAST however both of these programs are independent of the Baker WinAST software application To use the troubleshooting application a user should be familiar with the hardware design of the Baker WInAST Test lead and feedback lead assignments are perfor
84. sary to properly program these pages A copy can be obtained from Baker at CMC Fort Collins 1 800 752 8272 if not available Select the Lead Map button at bottom of page Enter the correct digital output line for the lead map of the WINAST unit If open lead is hardware built then input the digital output lines for its lead map For 3 lead units the correct settings are achieved with the Default button The WINAST unit will not operate correctly if these numbers are not correct Next in the Resistance folder at right choose the required Resistance Balance Formula and the Max Resistance hardware build for the WINAST unit In the AC Hipot folder select the Max AC Current that is hardware built for this WINAST unit In the Surge folder the Sample Rate is selected for the necessary sample rate which is customer part dependent Consult Baker about this setting Default is 5 MHZ The Rotation page is a list of the necessary digital input and output lines hardware build decided to operate the rotation tests if installed Almost all 99 of all Baker WinAST units will use the same Enable Rotation Sensor 38 Sensor Station Select 39 Enable Rotation 21 Sensor CW 16 and Sensor CCW 17 digital lines Consult Baker if different The Phase 1 2 amp 3 digital lines will apply rotation power during Rotation Test 1 of the Master Phase 4 5 amp 6 digital lines will apply rotation power during Rotation Test 2 Phase 7 8 amp 9 digital lines w
85. select next then finish You do not have to restart the computer yet Run the Add Hardware from the Control Panel Next choose Yes have already connected the hardware option Select Next Select Add new hardware device Choose the Install the hardware that manually select from a list option Select Baker Drivers Choose the Have disk option and choose the Browse button Locate the Dio 0x300 inf file in the C Baker Drivers folder Open it and select OK Select DIO 0x300 from the list and select finish You do not have to restart the computer yet Repeat step 3 for the fastatodio2000 driver If you are installing WIN2000 you will have to reboot the computer after loading all drivers If the WINAST unit is built with a second DIO board you need to load the drivers for it The Inf file is located and installed as in step 3 For Windows XP to make the drivers active open SYSTEM Device Manger and Baker Drivers Right click the first driver AIO and select properties Left click the folder Resources and left click the button labeled nsta Drives Manually Close the properties window but do not restart the computer Repeat these steps for each the Baker drivers to make them active Restart the computer WinAST customer selections for a specific unit contact SKF CMC Fort Collins di The proper operation of the WINAST unit depends on the correct programming of the configuration file When completing this section a copy
86. should be made of the Sysconfig cfg and VOcontig cfg files into the C Baker 7EMP directory It is also important to write protect these files to avoid corruption by accidental use Double click the C Baker Dalconfig exe to open the Oconfig cfgfile Set the Number of Stations box and the Number of TL Mux Boards box Then select the tests that the unit will be running This is dependent upon the hardware build of the WINAST unit If a PLC is to be used select the Master box and enter the correct digital lines as per the hardware build Next Baker WinAST User Manual enter the correct digital input and output lines for Station 1 default and if used Station 2 These also are based upon the hardware build of the WINAST unit In the System I O area enter the station switch 1 if there is a dual station and no station switch and keylock 1 digital lines if used Hardware builds Again if a PLC is to be used there is a box for Miscellaneous 1 0 digital lines again dependent upon hardware build When complete click the close file in the upper right corner Click the save option Right click the file Oconfig cfg and select properties Select Read Only to protect 3 Double click the C Baker Sysconfig exe program to open the Sysconfig cfg file Set the of Stations box the of Leads per Station box hardware build the Language of choice and the WINAST SN The Options area is used for optional hard
87. st column Line lengths must exceed 80 characters Line numbers must be in consecutive order i e Line 8 must precede Line 9 Do not add any lines Sd UM cp TS Normal ranges are indicated in type brackets Baker WinAST 1 5 User Manual 8 Line1 Cal file type DO NOT CHANGE THIS LINE 2 0 546 Line2 DCI SLOPE Open circuit 5 6 HV 3 10 Line3 DCI INTERCEPT Open circuit 50 300 HV 3 0 116 O Line5 DC CURRENT INTERCEPT into load 0 33 07 62 876 62 95 63 322 6 238 Line10 CAL 2000 OHM HI 59 61 20k x10 gt 1333 6 246 6 308 0 6183 Line13 CAL 200 OHM HI 059 061 20k x10 gt 133 0 6193 0 6295 0 06198 0 06203 0 06285 0 006253 Line19 CAL 2 OHM HI 00059 00061 20k x10 gt 1 33 0 006238 0 006275 0 0006181 0 0006176 0 0006297 Line24 CAL 200 MOHM LO 000059 000061 20k x10 0 066 0 00006056 Line25 CAL 20 MOHM HI 0000059 0000061 20k x10 gt 0 0133 0 00006357 0 00006072 0 00000603 0 000006011 0 000006 10 11 19 425 28 854 38 096 2 18 10 1 438 0 Line38 AC V INTER 2 ESA 3 5KV 0 407 0 06398 10 8034 0 0042 0 5 0 0088 0 Line44 AC INTER 2 ESA 40RV 750 0 06 5 Line46 AC V OL STEPS OpenLoop seek 5 20 0 1165 Line47 TEMP GAIN ST1 SolidState 1177 2 InfraRed 1 2 0 1154 0 Line50 TEMP OFFSET deg Kelvin InfraRed 0 SS 273 0 5 0 5 450 1 Line54 INT AC TIME slow uP 10ffast uP
88. t shall remain in full force and effect This product license sets forth the entire understanding and agreement between the parties and no written or oral representative of any kind whatsoever shall in any way modify or expand the terms of this User s Manual In the event of any conflict or inconsistency between the terms of this product license and any documentation this agreement shall preempt such documentation to the extent inconsistent NOTICE All material associated with this product 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 Baker WinAST User Manual Investigation investigates allegation of criminal infringement for enforcement Important notice concerning warranty and repairs The warranty is void if i the UNIT is shipped without shock absorbing packing material ii the UNIT is damaged by improper use iii any party other than SKF modifies the Software or loads or operates unauthorized software programs on the UNIT or iv the User has breached the Product license set forth above The User assumes all responsibility and expense for removal reinstallation freight or on site service charges in connection with the foregoing remedies SKF s liability to purchaser relating to the product whether in contract or in part arising out of wa
89. t that will light during a test e Start Button Green button that can be used to start a new test e Retest Blue button that can be used to retest a part e Fail Red button that that acknowledges a failure When a test fails a choice needs to be made to either retest or acknowledge the failure In order to test a new part the failure from the original test or the possible re failure of the retested part must be acknowledged e E Stop Emergency stop that removes 12v power from the system 2 Master Enable Button Enables the system to test parts turns on 12V E Stop power 3 Menu Access Lock Unlock In locked position allows only restricted software access tests can be run but not changed Control Panel Fixtures Figure 2 3 Control Panel A control panel of some type is furnished with each machine Depending on customer configuration and requirements this panel can look different however it will always have this set of six buttons If a fixture Is purchased by the customer there will be an attached control panel If a fixture is not purchased the control panel will be located on the instrument itself as seen if Fig 2 2 Baker WinAST statistical information Statistical information is stored in two operational modes One is to store statistical data on all parts that are tested on the unit within the period set by the operator when a Restart reset counter command is given A history of the prior counts is save
90. tance please contact Baker Instrument Company an SKF Group Company to discuss the terms Please refer to the original quotation for Warranty Information Specifically please note that the warranty for any board with relay s is six months For pricing or replacement boards contact Baker Instrument Company an SKF Group Company 4812 McMurry Avenue Fort Collins CO 80525 970 282 1200 FAX 970 282 1010 800 752 8272 Installation Check List Installation was performed at Installation Performed by Customer Witness of Installation The following items are to be checked and initialed by the customer in the presence of a Baker Instrument Company an SKF Group Company representative 1 All boxes crates were received in good condition with no apparent shipping damage 2 Please check to indicate completion of installation of the Baker WinAST and accessories Terminal and Keyboard Disk Drive Temperature Sensor Data Lock Keys Printer and Cable RS232 Communication Port 3 Test Fixtures were installed to customer satisfactions 4 Please check to indicate that the Baker WinAST pass the following tests AC hipot Arc Test Did tester detect an arc and terminate the hipot Test Did Tester survive arcing DC hipot Test Surge Test Resistance Test Rotation Direction 5 A manual was received with the correct documentation for this particular Baker WinAST Baker WinAST User Manual Baker WinAST User Manual 6 The Ba
91. testers provide the DC hipot test as an alternative to the AC hipot test The DC hipot leakage current is only affected by the quality of the insulation resistance When a DC voltage is applied across an insulator initially there is some capacitive charging current But this decays to zero leaving only the resistive current Although it is more commonly used in predictive maintenance situations some manufacturers especially of larger motors find it useful to measure insulation resistance The DC hipot test takes more time to conduct because of the charging and discharging times of the windings Knowledge of the real behavior of resistors not just ideal resistors will help the operator to test the winding insulation to a point before the insulation is broken down j t a g ath 6 ake T Voltage gt Voltage Figure 1 1 Principle of Resistance For an ideal resistor as the voltage is increase the leakage current will increase proportionately However insulation resistance in the real world rarely behaves in this manner Instead the current in a typical resistor will increase proportionately with voltage until the voltage is within as little as 5 of the breakdown voltage Just before insulation breakdown the current will rise faster than the voltage At still higher voltage the insulation will completely breakdown and the current will rise extremely fast Baker WinAST User Manual Baker W
92. tests1 6 Principles of rotation direction testing Getting started General information Instrument connections Interconnection of fixtures and accessories requirements Setup Comprehensive test capabilities AC amp DC hipot tests Resistance test Impulse surge test 1 1 1 2 1 3 1 4 1 7 1 8 1 8 1 8 1 9 1 9 1 9 1 9 1 9 1 8 WinAST8800 User Manual Baker WinAST User Manual Partial discharge corona test Field strength test optional Rotation test optional Operational controls Programming the software Modifying the software Running tests Options Utilities Standards and safety Introduction to general maintenance Calibration Self test and troubleshooting Test fixture interface Software maintenance Baker WinAST Windows software installation1 1 1 10 1 10 1 15 1 37 1 40 1 1 1 1 1 1 1 1 1 1 1 1 1 1 TOC 3 Baker WinAST User Manual Important Safety Information Preface Important Safety Information Baker WinAST User Manual General safety precautions gt 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 gt If using the equipment in any manner not specified by SKF the protection provided by the equipment may be impaired Safety term definition DANGER This notification indicates a hazar
93. the right in the sequence of tests Since Res 3 6 is the last conducted of the three tests this is the menu where the balance test is programmed 8 To activate the calculation under Tests for Comparison scroll to the other resistance tests which need to be included in the calculation and left mouse click them If multiple selections are desired press and hold the Ctrl key and click together for each additional entry They will turn dark blue when active All resistances which are dark blue as well as the test in the present programming menu will be compared for balance 9 To deselect a test from the balance calculation press the Ctrl key when the left mouse click 10 Lastly enter the percent balance limit The results screen shows the calculated balance error highlighted The displayed value will be beneath the measured value for the test in which the balance test was programmed Edit AC hipot test limits 11 Highlight or tab and type the appropriate A value for MaxTotal 12 Highlight or tab and type the appropriate A value for MinTotal Fig 3 19 Edit AC hipot parameters The minimum leakage current is used to verify that the ground is attached in situations where the ground is manually attached to the core by the operator Otherwise set the minimum to zero The minimum current value is always compared to the total current even when Capacitive Compensation is active This is because the resistive current may be too small to ver
94. the voltages at 1000V intervals up to 3500V Adjust line 18 AC V SLOPE to adjust the voltage calibration Increasing this number will decrease the slope NOTE The voltage on the AC hipot will fluctuate and may read higher than the programmed voltage momentarily The voltage will be steady for the actual time of the test l Check the open circuit current Set the unit with neither leads nor probes connected A reading of 5 mA is normal at any voltage Check the leakage current calibration Attach a 02 uF 5Kv minimum voltage capacitor across TL1 and Ground If the AC hipot is a 13 mA hipot use a 01 uF load NOTE Disconnect any voltmeters and probes from across the load 7 5 mA leakage current should exist for every 1000V of output with the 02 uF load 3 5 mA per 1000V should exist with the 01 uF load These results can be verified by placing a current meter in series with the load on the LOW voltage ground side Perform this test at 1000V intervals up to 3500V If the current does not match follow the procedures m With no probes or meters attached check the current open lead leakage current at 1000V intervals up to 3500V If the current is inaccurate by constant percentage across the range then adjust line 24 AC SLOPE in the cal txt file Increasing this number will increase the slope Check the current again n Ifthe current reading is constant across the voltage ranges adjust 25 AC INTER to a lower value until a reading of 0
95. ther Simply close or mouse move the graph to see the waveform for another surge test Baker WinAST User Manual Baker WinAST User Manual 20 Click accept on the top level for an individual surge test or click on accept under the all time slots to accept all surge tests Using the partial discharge corona test Baker has incorporated a method for detecting the presence of partial discharge into the standard high voltage impulse test used to check for breakdown Modifications to the traditional impulse test hardware circuit were necessary The impulse A D circuit was modified so that the high frequency partial discharge energy is not attenuated before the impulse waveform is digitized The digitizing circuit samples the waveform at high speed so that the high frequency component can be captured More sampled data is stored so that the high frequency components can be properly displayed and analyzed Software algorithms are used to separate the high frequency component from the low frequency impulse waveform The low frequency waveform is displayed and analyzed using our patented Error Area Ratio analysis method as before The high frequency data is displayed and analyzed using a Sum of the Delta Ys calculation to quantify the corona data in to a single value This value is calibrated to convert it to Coulombs After learning the shape of the surge waveform from a known good winding the user can also set a window defining the start tim
96. turn 1 Safety Switch 2 Safety Switch Return Test Status Connector TESTING PASS and FAIL and other lines output These outputs are wired parallel with the control console lamps The TESTING line outputs when a test is in progress The PASS or FAIL line is activated when the test is complete indicating test outcome Model No Pin Number TBD 13 Software maintenance Baker WinAST Windows software installation CMC Fort Collins an SKF Group Company Updated 24 August 2012 by John White Systems Field Engineer Installation of Windows XP 1 E 10 0 nO c ROO 13 14 15 16 17 Enter BIOS and setup CDROM to Boot Boot up the computer with the Windows XP setup disk installed When prompted press enter Scroll thru licensing agreement using page down and press F8 Create partition in un partitioned space press C Create partition to full size of hard drive enter Install Windows on highlighted partition press enter Format using the NTFS file system press enter Setup will format the partition and choose location for files WINDOWS press enter Setup copies needed files to hard disk Install default files Gathering information click next Enter name as BAKER organization as BAKER the click next Enter OEM number from the original booklet when prompted and click next Enter computer name as BAKER administrator password as baker confirms with baker next
97. uickly if they do not also pass a partial discharge test Partial discharge has become a major concern in motors operating at nominally low voltages i e under 600 volts due to the effects of variable speed inverter drive systems Variable speed drives are notorious for causing frequent over voltage transients which far exceed the nominal operating voltage These transients can exceed the corona Inception Voltage CIV and therefore generate ozone damaging the insulation of low voltage motors slowly over a long period of time The inverter drive transients are best simulated by the high voltage impulse test rather than the hipot test The hipot test only tests the ground insulation The high voltage transient applied by the impulse test stresses the phase and turn insulation like the inverter transients When a high voltage impulse is applied to a winding and the CIV is exceeded low energy wide bandwidth electrical discharges are generated It is beneficial to detect these discharges or the absence of them as a means of ensuring that the insulation system of a motor will have a long life when used with an inverter Partial discharge technology has been pioneered primarily by the predictive maintenance industry which uses it to detect the onset of premature insulation failure in high voltage windings Since these windings operate in a high voltage environment it is possible to monitor for the presence of or increase in partial discharge under nor
98. uild instructions for the necessary digital lines to engage for each motor type hookup are needed This can be obtained from CMC Fort Collins at 1 800 752 8272 This information is formatted to match the software The first line is for organization and is ignored The second line denoted a configuration to follow The third line is always the same hold over from Cobra software The fourth line is the motor type name This name is critical to be formatted correctly for the software to recognize it The fifth line is to describe to the software which digital line to toggle for the relay matrix The sixth line is for structure to alert the software how many lines of information will follow The actual motor lead hookup the relay matrix is doing for surge and rotation The file will be given with a space in from of line 4 the motor type This will prevent the name from being given in the operator setup of a master To enable the connection just remove the space from in front of the motor type Do not change the format of the name As with the plc and barcode setup check the ARM box in the sysconfig cfg as described in the AST Customer Selections For Specific Unit instructions above for the ARM configuration to work The resistance summation formulas for each motor type are embedded in the software These are referred to by the enabled configurations NOTE If there are two or more digital lines necessary to operate the relay matrix add line
99. ured Current A 1000 2000 3000 4000 5000 Resistance test Test Instruments Cambridge Tech model 510 Micro Ohm Meter Cal Due Fluke model 8062A Multimeter Cal Due Resistance Range Actual Resistance Measured Resistance 1 10 Baker WinAST User Manual 2 20K Ohms Optional 200 Ohms 2K Ohms Optional 20 200 Ohms 2 20 Ohms 0 2 2 Ohms 0 02 0 2 Ohms lt 0 02 Ohms lt 0 002 Ohms Optional Baker WinAST User Manual 18k 10k 2200K 1800 1000 220 180 100 22 Surge Test Test Instruments Tektronix model 2430 Digital Oscilloscope Cal Due Tektronix model P6015A High Voltage Probe Cal Due Open Circuit Test Program Voltage V Actual Voltage V Display Peak Voltage V 1000 2000 3000 4000 5000 Temperature Test Instruments Fluke model 77 Multimeter Cal Due Fluke model 80TK Temperature Probe Cal Due Actual Temperature Measured Temperature Baker WinAST User Manual Baker WinAST User Manual 11 Self test and troubleshooting Baker WinAST mantest procedures NOTE This procedure is provided to the customer as a tool for diagnostics and troubleshooting of the Baker WinAST tester It is software that manually controls relays and power supplies without the safeguards of the Baker WinAST testing software Only qualified personnel should use this procedure with quidance from SKF Condition Monitoring Center Fort Collins 1 800 752 8272 The improper
100. ware used on this specific unit The ARM is checked if an auxiliary matrix is installed in this unit The IR probe is checked if Exergen Infared probes are used If left unchecked the unit will default to the Solid State temp probe of most units 4 The PLC box is checked for PLC operation and number of Master lines The corona box is checked only if corona hardware is installed The Fail Printer is checked only if fail printer software is installed in Windows The Barcode Serial Interface is selected when a serial number input via the RS232 input or a USB barcode scanner is to be used It must be set up according to manufacturers specs The Two State Leads box is checked if the unit DOES NOT HAVE OPEN LEAD ABILITY via the hardware build This will by default only give a choice during master building of active or grounded lead For open lead a third choice of open is given A hardware build open lead machine is necessary for this to work The Station 2 Cal Temp Gain is to be checked only if a Station 2 temperature sensor us used The Temp Comp box is checked if temperature compensation is to be used in the operation of the WINAST The Station 1 and 2 Auto Start digital input lines are hardware chosen and entered here 18 amp 19 Along the bottom is the Test Bus area Select the tests that will be used on this WINAST unit hardware dependent 5 This section will deal with the Lead Map and testing parameters A copy of the hardware lead map is neces
101. with an Baker WinAST If the Self Test passes there may still be a hardware failure associated with the test lead relays Document the data collected from the Self Test as well as the results from production testing and contact a Baker technician for assistance with additional troubleshooting Baker WinAST User Manual Baker WinAST User Manual 8 Standards and safety Publishing and documentation Information furnished in this manual by Baker Instrument Company an SKF Group Company is believed to be accurate and reliable However Baker Instrument Company an SKF Group Company 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 an SKF Group Company 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 except for the enclosed Calibration Check Sheets in Chapter Nine without the expressed written permission of Baker Instrument Company an SKF Group Company Electrical and calibration standards All Baker Instrument Company an SKF Group Company standards are either certified directly or are traceable to certification by the National Institute of Science and Technology NIST formerly the United States Bureau of Standards

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