Baker AWA IV QRG - EN
Baker AWA IV QRG - EN
Baker AWA IV QRG - EN
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Contents
Item Description
1 VGA port—used to connect the tester to a larger monitor (not included) for easier viewing of
test results.
2 USB ports—Industry standard USB ports are accessible from the front panel for connections to
a printing device, and data storage and retrieval devices.
3 Ethernet connector—The tester can be connected to a network via the ethernet connector.
4 E-stop equipment power shut-off—This large, highly visible red button is easily pressed on the
front panel for equipment shut-downs. It cuts all power to the unit swiftly and safely.
5 DC test/HiPot button.
6 Open ground light.
7 Leads energized light.
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Instrument Descriptions
Item Description
8 Test leads 1–3 select buttons.
9 Voltage output control knob—Turn the knob clockwise to increase the applied voltage or
counterclockwise to decrease the voltage. The rate of voltage increase or decrease is set via
the touch window interface. Do not force the knob; turning the knob harder does not cause
voltage to ramp any quicker and may damage the instrument.
10 High-voltage test leads—The Baker AWA-IV uses high-voltage test leads for surge, Baker
ZTX, and DC testing. Three test leads (red) and a ground lead (black) are provided for motor
test connections. Both sides of the connection clips must be in contact with the terminal of
the motor being measured. You must keep the leads clean and dry for best measurement
performance.
11 Resistance leads—For the AWA-IV 2 kV and 4kV models, one red test lead and one black
ground lead are used for low-voltage testing.
CAUTION: The test leads have exposed metal areas. Do not touch the leads while tests are running. Always ensure
that the test leads are not placed in proximity to the frame or ground potential.
Both sides of the connection clips must be in contact with the terminal of the motor being measured. Most recent
AWA-IV 2/4kV testers have two low-voltage resistance test leads. Ensure that the leads are connected as shown in
the example below.
Fig 3: Front panel controls for Baker AWA-IV 6 kV and 12 kV models.
Item Description
1 VGA port—used to connect the tester to a larger monitor (not included) for easier viewing of
test results.
2 AUX/Power Pack connector.
3 USB ports—Industry standard USB ports are accessible from the front panel for connections to
a printing device, and data storage and retrieval devices.
4 Reset button.
5 Ethernet connector—The tester can be connected to a network via the ethernet connector.
6 Reset button.
7 E-stop equipment power shut-off—This large, highly visible red button is easily pressed on the
front panel for equipment shut-downs. It cuts all power to the unit swiftly and safely.
8 Open ground light.
9 Voltage output control knob—Turn the knob clockwise to increase the applied voltage or
counterclockwise to decrease the voltage. The rate of voltage increase or decrease is set via
the touch window interface. Do not force the knob; turning the knob harder does not cause
voltage to ramp any quicker and may damage the instrument.
10 Leads energized light.
11 DC test/HiPot button.
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Instrument Descriptions
Item Description
12 Test leads 1–3 select buttons.
13 High-voltage test lead, black, ground.
14 High-voltage test leads—The Baker AWA-IV uses high-voltage test leads for surge, Baker
ZTX, and DC testing. Three test leads (red) and a ground lead (black) are provided for motor
test connections. Both sides of the connection clips must be in contact with the terminal of
the motor being measured. You must keep the leads clean and dry for best measurement
performance.
15 Resistance leads—For the 12 kV models, three test leads with no ground lead are used for
low-voltage testing. The clips and cord color can vary depending on the design. AWA-IV 6 kV
models do not have this set of leads.
CAUTION: The test leads have exposed metal areas. Do not touch the leads while tests are running. Always ensure
that the test leads are not placed in proximity to the frame or ground potential.
The AWA-IV 6 KV model differs from the AWA-IV 12 kV with respect to test leads and procedures for use.
The AWA-IV 6 kV analyzer uses only one set of leads for both high- and low-voltage testing; it does not include a
separate set of low-voltage resistance test leads.
The clips are currently rated for 48 volts. Ensure that the clips are not placed in proximity to the frame or other
ground potential.
Process Overview
The basic process for testing a motor on the AWA-IV includes the following steps:
3. When creating a new database, a dialog box will open so you can name the new database. Enter the database
name in the field then click OK.
4. When opening an existing database, highlight the database needed from the list and click OK.
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Preparing for Testing
NOTE: Windows login default password: baker Test parameter setup default password: bakerpas
4. To change a password, click on Change Password, type in the current password (default or most recent), enter
the new password and confirm, then click on Set Password.
5. Click OK to close the password dialog box.
6. Click the Add button. The Create New Test ID dialog box appears.
7. If an existing Test ID is close to what you will need, ensure that it is selected in the Test ID field then click on
the Copy Current Test ID radio button. Otherwise, click on the Add Blank Test ID radio button to start from
scratch.
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Preparing for Testing
8. Give the new Test ID a descriptive name and choose a target motor voltage class from the drop-down list then
click on OK.
9. You can further modify the Test ID by selecting the desired tests to be performed via the ON/OFF buttons.
Fig 9: Selecting tests to perform, and controls for configuring or viewing test parameters.
10. You can also provide specific values and parameters for each test as needed by clicking on the Configure/View
buttons. In the following example, DA Only is selected from the DA/PI tests drop-down list and Ramp Voltage is
selected from the HiPot/Step Voltage test list.
Fig 10: Selecting test parameters from the DC Tests Setup window.
11. Click Save to save the changes made to the new Test ID or click OK in response to a confirmation dialog
appearing after making parameter changes. The new Test ID will be added to the list.
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Preparing for Testing
NOTE: The labels for the Location and Building fields can be changed as desired by using the Options Changeable
Labels items in the View tab.
4. Best practices suggest adding all information pertinent to the motor to facilitate testing. This information can be
useful during the testing and troubleshooting processes.
5. Click on the Save button to add the motor information to the database.
6. The Select Test ID dialog box will appear so you can assign the most appropriate Test ID to the motor. Test IDs
contain the testing parameters (for example, tests performed, voltages, and pass/fail criteria) along with a basic
motor description. For example, a Test ID named 480Vw/Rotor>100HP StepV includes tests for a 480-volt motor
that has the rotor installed during testing, is less than 100 horsepower and will feature step voltage testing.
7. Click OK after selecting the best available Test ID for the motor you will be testing.
Fig 11: New motor added to Motor Tree. Information entry and Test ID selection.
8. The new motor will appear in the motor tree on the left side of window.
9. You can then view the tests selected for the motor along with the test parameters then make adjustments if
needed to better suit your testing objectives.
Fig 12: Selecting tests to perform, and controls for configuring or viewing test parameters.
NOTE: The following sections provide brief introductions to each test setup window. For details on the windows and
the parameters set within, refer to the AWA-IV user manual.
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Preparing for Testing
4. The Test Results section shown at the bottom of the window provides a view of the results collected when the
test runs automatically or semi-automatically. You can also use this section directly during manual testing.
5. When you have completed your setup, close the window.
Setting Up DC Tests
1. Open the DC Tests setup window by clicking on any of the voltage buttons to the right of the DC tests listed.
2. Using this window, you can enable or disable test types, select DC test types to include in your testing, select
specific parameters to include in your testing, or adjust testing parameters to fit your needs.
3. You can use the default values provided, or you can modify parameters based on IEEE, EPRI, EASA, IEC, or
company standards.
4. Depending on the test types selected, other controls may appear within the window.
5. If you want to use temperature correction for your DC tests, check the Temp Correction Enable box (even if you
have checked this option in the resistance test setup window.)
6. The Run Test buttons near the bottom left of the window are used to control testing during manual testing. The
Voltage and Current displays to the right show you value being measured during testing.
7. When you have completed your setup, close the window.
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Preparing for Testing
3. Add or delete steps within this window as needed, then click Finish to save the setup.
4. When you have completed your setup, close the window.
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Preparing for Testing
WARNING: When using ZS Override, test voltage will not start at zero. Because the tester will
immediately apply higher test voltages to the motor, take all precautions to avoid injury or death from
severe electrical shock.
6. The large graph area plots the surge waveform during testing.
7. The Run Surge controls are used during manual testing.
8. When you are satisfied with your specifications, close the Surge Test setup window.
When you have completed the processes for selecting an existing motor ID, creating a new motor ID (and Test ID),
selecting tests to run, and confirming or modifying test parameters, you will be ready to run the tests on your motor.
Details for running tests automatically, semi-automatically, or manually are provided in the next section along with
other operating procedure information.
The surge test is load dependent. Anything that adds capacitance to the motor or system under test will create more
load on the tester.
When surge testing a motor, all capacitors should be removed or the ground should be lifted. Otherwise, the
capacitors will absorb the surge pulse, preventing it from entering the coils.
When possible, remove or secure the rotor before testing. Rotors can affect testing results, particularly if they move
(even slightly) during testing. Some issues can be erroneous high resistance imbalance in coil testing due to increased
inductance, inability to polarize for DA/PI testing, or frequency shift in one or more waveform values during surge
testing. An erratic PP EAR will often result, and the shift could even trip the EAR limits.
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Preparing for Testing
Using the Explore, Motor ID, and Route Tabs to Find Motors
The left side of the window is used to navigate through the motors within the opened database. Three methods can
be used:
The Explore tab includes a tree structure to help you select a particular Motor ID. The two upper levels of the tree
correspond to the location and building in which the physical motor is housed. Location and Building are the default
tree labels, but they can be changed. The lowest level is the Motor ID.
The Motor ID list box provides an alphabetical listing of all motors found in the database. In the edit box located
above the list, the currently selected Motor ID is displayed. Locate a Motor ID using one of two ways within this tab:
Begin typing the desired Motor ID in the edit box. The list will automatically scroll to the nearest Motor ID that
begins with those characters.
Otherwise, scroll down the list until the Motor ID is located. Double click on the Motor ID or highlight the Motor
ID and click the Display button to select.
The Route tab allows construction of individual lists of Motor IDs for routing purposes. As seen in the example, the
“Spring Outage” list is selected. This list has four associated motors.
You do not need to search the entire database to find the motors to be tested during the “spring outage” event. This
tab also allows you to edit and print the routes.
To select a motor, simply click on the motor name in the route list. Click on the Edit Route button to start the editor.
The Route Editor dialog box appears to help you add, rename, and delete routes. It also provides tools to add,
remove, and change the order of the Motor IDs within a list.
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Basic Testing Procedures
You can run tests semi-automatically by clicking on the individual test type buttons found in the Tests tab. The
software will perform the same functions as during automatic testing, but only for the selected test.
As noted in the setup window descriptions, each window has controls for manually executing tests. Resistance and
surge tests even allow you to test individual leads. Tests can also be run manually using the analyzer’s front panel
controls.
1. Resistance
2. Megohm
3. PI/DA
4. DC HiPot/DC Step Voltage
5. Surge
NOTE: The actual tests performed will depend on the tests you select for your motor.
At the end of the sequence, the test data will automatically be saved to the database.
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Basic Testing Procedures
4. The Safe To Turn On dialog box appears when a high-voltage test is selected. Typically, it instructs you to verify
that the correct set of leads have been properly connected; however, the content of the message can vary
depending on your tester configuration.
Fig 22: Safe to Turn On dialog box; message content can vary.
5. Follow the instructions in the dialog to continue the testing process. When all tests have been run, the test data
will automatically be saved to the database and the main test window will re-appear.
NOTE: Not all Baker AWA-IV testers have low-voltage test leads. If this option is not available, this window will be
slightly different; however, the test operation is the same.
Test Sequence
The following sequence of tests will run automatically. If a test fails, the software will stop the testing process, leads
will be discharged and grounded, and you will be presented with choices for continuing testing if applicable.
Under most circumstances, you should troubleshoot, diagnose, and repair the motor before going on to the next test
in the sequence.
Temperature Entry
The Temperature/Resistance dialog will be displayed ready for the temperature reading to be entered from a third-
party temperature device.
1. Enter the temperature off the motor and click the Accept button to acknowledge the temperature being
entered.
2. Click Next to proceed. The tester will automatically proceed with the remainder of the tests.
Resistance
This test looks for resistance imbalance between phases. If a large imbalance is found, inspect the motor for causes
of the discrepancy. By comparing the values to a reference standard, you can evaluate the following quality and
degradation issues:
Field testing—Inspect connections in junction box and look for high resistance connections, and improper or loose
connections.
Quality/post failure—Look for number of turn per phase variation, diameter copper variation, turn-to-turn shorts,
or turn opens.
Megohm
A Megohm test uses a test voltage close to the motor’s operating voltage and appropriate standards and/or company
guidelines. This voltage will be held for 60 seconds during which the analyzer watches for overcurrent conditions and
micro-arcs or insulation resistance values below the minimum megohm setting. Look for an unusually low Megohm
value when compared to previous measurements or industry accepted limits. If a low Megohm value is measured,
inspect the motor for ground wall insulation damage.
PI/DA
The Polarization Index (PI) test measures the insulation’s ability to polarize. When an insulator polarizes, the electric
dipoles distributed throughout the insulator align with the applied electric field. As the molecules polarize, a
polarization (absorption) current develops and adds to the insulation’s leakage current. The additional polarization
current decreases over time and drops to zero when the insulation is completely polarized.
The PI test is typically performed at 500, 1000, 2500, or 5000 volts depending on the motor’s operating voltage. The
duration of the PI test is 10 minutes (600 seconds). The PI value is calculated by dividing the insulation resistance at 1
minute by the resistance at 10 minutes. In general, damaged insulators will show a low polarization index.
Many insulating materials do not easily polarize. If the 1-minute insulation resistance is greater than 5000 Megohms,
the PI measurement may not be meaningful.
The PI test is performed on motor 100 Hp or greater. Motors less than 100 Hp should use the Dielectric Absorption
(DA) test. On the AWA, set the PI minimum alarm at 2.0 for class B, F, and H insulation, and 1.5 for class A insulation.
The PI test should not be used as the basis for any motor acceptance criteria. It should be used as a trending and
diagnosis tool along with other test results, including the PI curve generated.
If the Test ID was set up for a DA test, the test duration will be three minutes (180 seconds).
DC HiPot/Step Voltage
The HiPot test is performed at a test voltage higher than the Megohm test; that is, at voltages typically encountered
at start-up. Actual test voltages are based on the motor’s operating voltage and appropriate standards and/or
company guidelines.
Look for unusually high leakage currents or a leakage current that does not stay constant. High leakage currents
indicate weak ground wall insulation.
During a Step Voltage test, voltage is applied to all three phases of the winding and raised slowly to programmed
levels then held for a predetermined period. This process is executed in equal increments (steps) until the target
maximum voltage level is reached. Because the test is most stable at the end of each step, data is logged at this
point. If the leakage current doubles from a given step to the next, an insulation weakness is indicated and testing
should be stopped. If leakage current increases consistently less than double, the motor insulation is likely good.
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Basic Testing Procedures
Surge
Effectively an electrical resonance test, the Surge test creates a non-linear voltage drop across the windings, stressing
the turn-to-turn insulation. If weak insulation exists, the differential voltage will short out a bit of the winding,
causing the overall inductance to go down.
Surge testing measures pulse-to-pulse EAR (Error Area Ratio) by default, and can also measure line-to-line EAR. (Refer
to the AWA-IV User Guide for details on Surge testing and EAR measurement.)
During testing, the voltage will be slowly increased on lead 1 to the voltage specified in the
Test ID. If no pulse-to-pulse EAR failures are detected, leads 2 and 3 will be tested.
A shift to the left in the waveform patterns is a common indicator of weak insulation.
The Results Summary tab (accessed from the bottom of the pane) presents a Date/Time section at the top of the
window and a spreadsheet style view occupying the main display area.
The Date/Time section shows a summary of the time and date of tests, and whether the tests passed or failed.
Clicking on a specific test date/time loads the test records for that event into the main display area.
The spreadsheet style of the results view shows the actual test data acquired. The test date and time are shown in the
first two rows. A header row marks the start of a results section for each test category followed by the specific test
measurement results. Color-coding helps you see whether a test category includes all passing tests (green) or failing
results for specific measurements (red).
The Surge, PI, and Step/Ramp Voltage test results can be viewed using the dedicated tabs found at the bottom of the
pane.
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Basic Testing Procedures
For example, review the PI test by clicking on the PI tab. The PI view will display the PI/DA graph along with a table of
the current and megohm readings gathered at specific times. The PI voltage, DA ratio, and PI ratio are displayed on
the right side.
The Surge test data can be reviewed by pressing the Surge tab
Printing Reports
Complete report generation features are available to document test results for managers, customers, owners, repair
personnel, and more. Reports contain test, nameplate, and application data and can be sent to a printer or output as
an RTF file.
The Select Filters section of the Report Generator dialog contains a selection of print filters. Check the Current
Motor/Test Results box, or use any combination of the filters such as a date range and all motors that fail any test
during a given test range.
The Select Reports section provides a list of available reports and report options.
The simplest report to generate is the current test results, which appear to the right of the Current Motor/Test
Results check box. Check the box then select which report(s) you want to generate.
NOTE: For more detailed information on printing reports along with additional information on testing, results
analysis, recommended test voltages, applicable standards, data transfer, and more refer to the Baker AWA-IV User
Guide.
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Local Sales Office
Megger USA - Fort Collins
4812 McMurry Ave., Suite 100
Fort Collins
Colorado, 80525
USA
T. 1-970-282-1200 or 1-800-752-8272
F. 1-282-1010
E. baker.sales@megger.com
Manufacturing Sites
Megger Limited Megger GmbH Megger USA - Valley Forge
Archcliffe Road Obere Zeil 2 61440 Valley Forge Corporate Center
Dover Oberursel, 2621 Van Buren Avenue
Kent GERMANY Norristown
CT17 9EN T. 06171-92987-0 Pennsylvania, 19403
ENGLAND F. 06171-92987-19 USA
T. +44 (0)1 304 502101 T. 1-610 676 8500
F. +44 (0)1 304 207342 F. 1-610-676-8610