SCHLEICH - EN - Bedienungsanleitung SurgeWin

Operating Manual
of the surge tester
for the devices

MTC2
MTC3
DSP1000
(MTC4)
SCHLEICH
ANTRIEBS- UND STEUERUNGSTECHNIK GmbH
An der Schleuse 11 D-58675 Hemer - GERMANY
Tel. +49 (0) 2372 / 9498-0 Fax +49 (0) 02372 / 9498-99
Im Internet: http://www.schleich.com
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Copyright by Schleich GmbH
Operating manual for WIN32 surge tester
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file : Q:\WINWORD\USER\ML\BAWIN32\PAWIN32\SURGEWIN\SurgewinE.doc
state : 1.9
last revision : 17.12.01

editor : M. Lahrmann, R. Penris, translation: G. Schellnack
date of print-out : 8/19/2014
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Never touch specimens or test leads during the test!!!
All statutory safety regulations must be followed! 2
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Index
1. Safety 4
1.1 Safety symbol 4
1.2 Attention 4
1.3 Regulations for safety at work 5
1.4 Important information for users of high voltage testing equipment 6
1.5 Notes for the operation of testing devices according to VDE 0104 8
1.6 Liability 9
1.7 General information on this manual 9
1.8 Copyright 9
2. Configuration of the test connections 10

3. Surge test 11
3.1 General information on the surge test 11
3.2 Set values 14
3.3 Generate new test step (or change) 15
3.3.1 Enter name of test step 16
3.3.2 Determine test connections 17
3.3.3 Enter test voltage 22
3.3.4 Enter test voltage 23
3.3.5 Determine the optimum display of the reference curve 24
3.3.6 Define evaluation methods 25
3.3.7 Store reference curve 28
3.3.8 Specific optimization of the setting 29
3.4 Process further test steps 31
3.5 Print 33
3.6 Detail indication surge test upon test process 34
4. Insulation resistance test 35

4.1 Theory insulation resistance test 35
4.2 Input of set values 38
4.3 Detail indication 42
5. Partial discharge test 43

5.1 Theory partial discharge test 43
5.2 Settings for partial discharge test 46
6. Setup settings for the surge test 49

7. Hardware 51
7.1 Technical Data 51
7.2 Pin assignment of plug at surge draw-out unit 52
8. Subject index 53
9. Annex 55
PLEASE NOTE THAT THE BASIS OF THIS OPERATING MANUAL IS THE GERMAN ORIGINAL, WHICH WILL ALWAYS
BE VALID IN CASE OF LEGAL DISPUTES.
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1. Safety
1.1 Safety symbol
You will find this symbol with all safety precautions and warnings in this operating manual where danger to life and
limb exists. Please follow these warnings and act particularly careful in these cases. All safety precautions and
warnings need to be passed on to other users. Apart from the information in this operating manual, the generally
applicable valid safety and accident prevention regulations must be observed.
1.2 Attention
You will find this Attention ! sign at places in this operating manual which must be observed very carefully, so that
the guidelines, regulations and indications and the correct operating process is observed. This is also necessary to
prevent that the testing device and/or other parts of the equipment are damaged or destroyed.
It will also be used where important additional notes are made.
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1.3 Regulations for safety at work
The following regulations for safety at work are to be strictly adhered to:
The tester has been designed according to the latest developments in technology and is operationally reliable.
However, should this testing device be used by unqualified personnel, in an inappropriate way or for improper use,
this testing device can be dangerous.
Each person in the factory of the user that deals with the installation, the operation and the maintenace of the
testing device GLP 2, must have read and understood the complete operating manual and particularly the
information on safety. We recommend that the user has this confirmed in writing (see annex).
Part of the intended usage is to follow the installation-, operating- and maintenance/repair conditions specified by
the manufacturer/supplier.
The tester may only be operated, maintained and repaired by authorized, trained and instructed personnel, which
must have participated in a special training about all possible risks.
Upon any kind of work concerning commissioning, operation, repairs and maintenance, the switching-off and
switching-on procedures indicated in the operating manual must be considered.
Any working manner that impairs the safety of the testing device must be refrained from.
The user is obliged to immediately report any change at the testing device that impairs the safety.
Unauthorized modifications and changes which impair the safety of the testing device are not allowed. All work on
the testing device must be done when it is voltage-free and switched-off.
Before commissioning and after maintenance/repairs it must be checked, whether all protection devices are
installed properly and functional. Protection devices must never be removed.
For the operation of the tester, take particular note of the regional safety regulations and regulations for prevention
of accidents.
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1.4 Important information for users of high voltage testing equipment
Caution! High voltage!
Touching high voltage can result in the loss of life. Equipment and accessories must be in perfect
condition and need to be checked regularly. The equipment may only be used in dry state and in dry
rooms. Only suitable qualified personnel or trained personnel under supervision of specialists should
work on this equipment.
1) Usage
The relevant regulations, above all VDE 0104, must be followed strictly. Every day before starting work,
equipment, accessories and supply line must be visually examined to ensure perfect condition. Every
user must familiarize himself with the safety notices in this manual and should be aware of all risks. He
is obliged to protect himself and others against accidents. Because of the necessary personal
responsibility, all users must be selected carefully and need to be trained in detail at least once a year.
The training must be put on record. Maintenance and alterations are reserved to the manufacturer.
(Unauthorized alterations endanger safety).
For checking, the test pistols can be sent (postage paid) to the manufacturer.
2) Working with test pistols

High voltage test pistols are only delivered with connected high voltage cable.
You will have full accident protection if you always use the test pistols in pairs, one in each hand. It is
very dangerous to connect the specimen tightly at one pole, to work with only one test pistol or to take
two test pistols in one hand.
The specimen which is supplied by the test pistols with high voltage must not be touched! Its insulation
could break down during the test. Do not test on metal surfaces because the voltage of the specimen
could be carried over to the surface.
During non-working time the high voltage must be switched off!
The test pistols are well insulated, but as protection insulated devices not grounded. Therefore the user
may feel a tingling or a slight vibration if he doesn't hold a test pistol tight after switching-on the
voltage, but touches it only slightly or has a very short distance from test pistol to the supply line. In
this case you can feel the electric field. A capacitive blind current of max. 0.08 mA could be flowing in
the capacity. (There is no danger up to 3.0 mA according to VDE 0104 !).
Only use test pistols in perfect condition with new value cable! Check test pistols and cable for obvious
damage every day before starting work! Faulty test pistols (even with the slightest fault at the device or
at the lead!) have to be put out of operation immediately and must be sent back to the manufacturer!
Attention !
For personal safety reasons, a 3mA test current limitation can only be done via hardware integrated in
the testing device. An adjustment of the maximum test current to 3mA by software, at which the device
is to switch off, does not serve for personal protection since the current can also reach higher values for
a short period of time.
Only a limitation by hardware of the max. possible current is allowed for personal protection.
This is done optionally inside the testing device by the means of a resistance. Only in this case the
otherwise necessary protection measures can be done without.
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3) Working with test covers
When working with test covers, please always take care that the high voltage can’t get out of the test
cover.
This can happen if, for example, the contact sheet for the case contact of the specimen is lead to the
outside.
It is also necessary to take care that absolutely no measure leads and connection leads go to the
outside.
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1.5 Notes for the operation of testing devices according to VDE 0104
Testing devices may only be operated under supervision and attendance of a electrical specialist. This applies to the
operation of test stations with and, in particular without automatic touch-guard. An automatic touch-guard is, for
example, a completely closed test cover under which the test takes place.
For the operation of testing devices it is necessary that operating manuals are available near the location of the
device.
Before every use, the operating material must be checked regarding possible damage that can be seen from the
outside.
Faulty or damaged testing devices that endanger personal safety may not be used.
All damage and faults at the operating material and at components of the testing device that have been detected
must immediately be eliminated by an electrical specialist or reported to the person in charge.
Only electrical specialist are entitled to do the maintenance of testing devices. This should, if possible be done in
coordination with Messrs. Schleich. We should like to point out that maintenance that is not followed by adjustment
of the devices could influence the accuracy of the measure results and the “go / no go” evaluation.
The safety equipment must be checked by an electrical specialist in appropriate time intervals, at least once a year,
regarding its perfect condition and efficiency.
In case of test stations where safety test probes are used, the testing personnel must also be informed about the
additional special risks.
The test setup must be in a way that a voltage carry-over to other conductive parts is not possible. We recommend
to use only measure leads with complete touch-guard and to insulate the test setup.
Before starting work, safety equipment must be checked whether it is completely operational.
If safety test probes are used, the user must check whether the test probes and the leads of the test probes are of
perfect condition before he starts work.
If there is a possible danger because of electric arcs, it is necessary to take measures to prevent personal injuries.
The electrical specialist in charge must convince himself that his instructions have been executed correctly before
the testing device is started.
It is not allowed to do maintenance and testing at the same time if this creates risks.
In case of faults it is possible that also parts of the test object and of the test station that are during regular
operation not carrying voltage take over dangerous voltages. If, in special cases, it needs to be worked on these
parts, suitable protection and helping aids are to be used (see DIN VDE 0105 part 1/07.83, sections 4 and 12).
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1.6 Liability
The testing device has been designed according to the latest developments in technology, checked and is therefore
operationally reliable. In case the tester is maintained or repaired improperly by persons not authorized by Schleich
GmbH, the liability will in any case be passed on to the owner. The same applies if the testing device is operated in
any other way than described in this manual. (see chapter Operative range and appropriate usage).
The user is obliged to operate the tester only in perfect condition. Messrs. Schleich GmbH is liable for mistakes and
omissions, with the exception of further claims, only within the framework of the guarantee commitments in the
order confirmation (respectively the commitments in the offer).
In view of the permanent development and improvement of our products, we reserve the right for technical
modifications at any time. Such modifications, mistakes and misprints do not imply a claim for damages.
Furthermore only original Schleich GmbH spare parts and accessories may be used. For any damage arising from
non-observance of the instructions in this operating manual Messrs Schleich GmbH do not assume liability. The
above information does not extend the liability- and guarantee agreements of the conditions of sale and delivery of
Messrs. Schleich GmbH.
This operating manual has been drawn up with the utmost care. However, Messrs. Schleich GmbH can not be hold
liable for possible mistakes in this operating manual and their consequences.
1.7 General information on this manual
This operating manual has been written with the intention to be read and understood in all details by those
responsible for the tester, for its setup and for its maintenance.
The complete documentation should always be kept within easy reach of the testing device. Details of great
importance for operating the tester are pointed out to in this operating manual.
Only the knowledge of this operating manual will ensure that mistakes with this testing device can be avoided and
guarantee trouble-free operation. It is therefore of great importance that this operating manual is known to the
relevant persons.
We recommend careful reading of this operating manual because we will not accept liability for any damage or
operating trouble resulting from disregarding this operating manual. Should you nevertheless have difficulty with
the operation, please do not hesitate to contact our service department.
Please note, that in case of temperatures around °0 Celsius (°32 Fahrenheit) (e.g. when delivered in winter) the
tester should warm up to room temperature before being switched on.
1.8 Copyright
Messrs. Schleich GmbH hold the copyright for this operating manual. This operating manual has been
written for the operating and supervising personnel of the tester. It contains instructions and technical
illustrations which may neither completely nor partly be copied, distributed or used for competition
purposes or given to a third party.
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2. Configuration of the test connections
Since the testers have an internal relay matrix, the coils that are to be tested can be connected to the connection
clamps in any way. In order to make sure that during the test process the tester connects the coils that are to be
tested correctly with the various testing devices, the coil connections for the various test steps need to be indicated.
Below please find examples of connection possibilities:
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4 5 6
All shown connection possibilities are imaginable.
However, in case the tester is also equipped with a sense of rotation test, there is a restriction. In this
case the connections are always combined to groups of 3 clamps each.
The reason for this is that for the sense of rotation test a three-phase voltage is connected to the specimen. The
connection groups are as follows:
group 1 clamps 1, 2 and 3

This means in case of the sense of rotation test, only the upper connection scheme could be used, because
beginnng and end of the coils are connected the same way as the completed motor is operated later on.
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3. Surge test
3.1 General information on the surge test
The surge tester is a modern winding tester for electric motors. The device is operated by a computer and offers a
great variety of possibilities to test stators and rotors. All parameters are filed in a higher-level data base.
Owing to its test method, the testing device allows accurate quality controls in the production or in the maintenance
of electric motors of all kind. Owing to the fact that it is computer-aided, the surge test is enlarged to a very
effective diagnostic system.
In contrast to conventional insulation test methods, the surge test offers an insulation test from winding to winding,
from coil to coil, from group to group, from phase to phase and, under certain conditions, also from the winding to
the case. It is to be mentioned that the insulation tests are done at a connected motor.
So far known test methods have only been able to detect insulation faults to the core and at unconnected motors
from phase to phase.
In order to be able to detect insulation faults within a winding branch, e. g. from winding to winding, it is necessary
to generate a voltage difference as large as possible from winding to winding, between the coil groups or between
the phases. In order to reach the high voltage differences, the surge test is used. A voltage impulse is switched on
the winding that is to be tested. The switching-on of this impulse takes place almost “instantaneously”. This is
the reason why the connection of the voltage is also described as surge voltage. Since the surge voltage is
connected to the winding only for a short period of time, there will be no permanent damage on the winding. With
the conventional high voltage test method, however, it is possible that, owing to a connection of high voltage for
too long a time, a destruction occurs. In practice, under the permanent stress of the motor, insulation faults usually
develop slowly from a minimal weak spot to a permanent fault.
If the surge test is used in the motor production, it is possible to do the test directly after winding and binding.
In this state of production, faulty motors can still be repaired at low cost.
As already mentioned in the general description, the surge test is non-destructive. This is achieved because the
surge high voltage is only connected to the coil that is to be tested for a very short period of time and therefore no
permanent current flow to the damaged part can build up.
The insulation fault is examined from coil to coil, from winding to winding, group to group, phase to phase and also
from the windings to the case. After the termination of all high voltage tests, the specimen is automatically
discharged.
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The surge test is a comparative test.
To do so the surge tester switches high voltage impulses to the connected winding parts. The impulses and their
behavior at the winding are displayed on an oscilloscope. The computer detects, compares and stores the voltage
waveshapes.
The high voltage impulse is generated by the very fast paralleling of a capacitor
loaded with high voltage with the windings that are to be tested. After
switching-on the capacitor, the stored energy discharges into the inductivity and
then back into the capacitor, etc. Owing to attenuation losses etc. a sinusoidal
damped oscillation is produced. This oscillation has a frequency and amplitude
+1500V curve that is characteristic for the inductivity which is to be tested.
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The surge tester registers this curve, then displays it and evaluates it.
Picture: typical voltage curve upon the surge test
The basic principle of the evaluation is based on the comparison of a reference curve that has once been detected
and the measured result at a specimen.
In case of a go result, the detected curve only differs slightly or not at all from the reference. In case of no go there
will be distinct variations in the amplitude, the frequency or in both characteristics.
Below we are showing you some examples.
picture: example of a deviation between the reference curve and the measured curve
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picture: example of a strong deviation between the reference curve and the measured curve
picture: example of a very strong deviation between the reference curve and the measured curve
For the examination of the surge curve, the testing device offers various fully automatic evaluation methods, which
can be applied all at the same time, partly or even individually.
These evaluations will be specified later on.
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3.2 Set values
The set values for a conventional test, e.g. ohmic measurements, are well-known in production. They can easily be
determined by means of mathematical calculation or metrological detection in the laboratory or test bay. They are
then available in members. For example for the set value a value of 135.5Ω is given for the coil resistance.
However, at the surge test not only one measuring value must be compared to a set value, but all measuring values
of the complete surge curve must be compared to a reference curve.
It is not possible, however, to pre-set the reference curves in numbers, e.g. by means of a calculation. They first
have to be detected individually through reference generation individually for each coil type. The storage of the
detected references is done under the same type name under which the other set values (e.g. resistances) are
stored.
By loading the specimen out of the data base later on, the set values and the reference curves are loaded into the
PC for measuring and don’t need to be entered again. The testing of the stators can then begin right away.
Since every stator constists of various phases (coils), an individual reference for every coil is generated.
For testing the stator is connected to the respective connection clamps of the testing device. The connection clamps
are numbered.
These connection clamps are then (in the individual test steps) automatically connected to the respective measuring
devices of the test station (e.g. resistance test, high voltage test, surge test, etc.). The connection is done
automatically by means of suitable high voltage relais.
Depending on the test system there are up to 12 clamps available for connecting the winding. These clamps can be
connected to every pole of the surge tester in order to generate the various reference curves and compare them to
the measuring curves.
For generating all this software, there is a so-called master mode, which is started with the command surge test.
The command can be found under the generic term set values. After calling the command, the tester shows for
example the following picture:
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3.3 Generate new test step (or change)
In the following description it is assumed that the surge test step is to be generated completely new.
We recommend the following procedure:
1. Enter name of test step

2. Determine test connections
3. Enter test voltage
4. Detect optimum form of reference curve
5. Determine evaluation methods and enter tolerances
6. Store reference curve
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3.3.1 Enter name of test step
In order to be able to first enter the name of the test step, activate the button Connections .
activate button „Connections“
Now the following picture appears:
Name of test step
Now enter the name of the test step. The text can be alphanumerical with a length of up to 40 digits.
During the actual test process, this text will appear on the screen as the name of the test step.
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3.3.2 Determine test connections
In order ot make sure that for testing the tester connects the correct leads of the specimen to the surge tester, the
test connections have to be entered. To do so please activate button Connections .
activate button „Connections“
Enter beginning connection of the

coil (during the test it is
connected to the + pole of the
surge tester)
Enter end connection of the coil

(during the test it is connected to
the ground of the surge tester)
Test connections
For the test it is now necessary to enter the connection of the start and the connection of the end of coil 1.
Example: If the coil that is to be tested is connected to the leads 1 and 2, the connections have to be entered as in
the above picture.
The numbers that need to be entered are the clamp numbers of the tester. In case you have allocated names to the
clamp numbers in the clamp table, these can be entered alternatively. (E.g.: Main, Aux, Common or Ha, Hi,
Com.)
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The following picture shows a typical connection configuration of a stator:
1 2 3 4 5 6
K1
Tester
Here you can see the standard contacting of a stator. For the input of the connections in the program, it is
absolutely necessary to use exactly these numbers. According to the design of the tester (number of available
connections), the numbers are 1,2,3 (4,5,6 - 7,8,9 - 10,11,12).
ATTENTION
In case of testers with enforced matrix, the clamps are no longer defined 1, 2, 3 etc.
With the enforced matrix, at the surge test, there are only fixed allocations between the tester and the clamps.
This special high current matrix is used, in case the surge tester is equipped with an additional 200nF surge
capacity.
This matrix is designed for a 6-clamp tester. Thus, a 3-phase winding can be connected as follows.
The matrix can switch the connections after the following scheme:
connection 1 against 2
In order to enter the clamp that is to be tested, always both numerical values need to be entered.
E.g. at connection 1 against 2 >> 1-2
at connection 2 against 1 >> 2-1 etc.
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PLEASE NOTE
It is important that at the input of both, clamp HV and clamp GND, there is a value. These are usually the same
values.
HV GND
e.g. 1-2 1-2
or 1-4 1-4
Also test inverse

Normally a coil is tested in a way that two tests with different connection polarity are done. This is shown by the
picture below on the left. The right picture shows the technical realization by means of the relais in the tester.
+
Surgetester + Surgetester + Surgetester
A test executed this way has the advantage that both coil connections are once carrying a high voltage (+).
With the option “Also test inverse”, the two tests can automatically be done in one test step. However, this is only
possible if the reference curve for both connection types is the same. This is often the case.
Option: Test also invers
Should the inverse reference curve be different, it is necessary to program two separate test steps.
In the first test step, the test connections of coil 1 are entered with 4 and 1 and in the second test step vice versa
wih 1 and 4.
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Connect core ground during the test

During the test it is also possible to connect the core of the specimen to ground. It is thus possible to generate
great voltage differences to the core.
The surge curve will normally look different than without core connection because the capacity between the surge
curve and the core influences the surge wave.
Surgetester +
Option: “Connect frame during

the test”
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Compare coils with each other

For testing a coil, normally always a reference curve of one or more “good” specimen is generated.
For the serial testing of large numbers of stators of the same kind this is no problem. In case of low numbers of
stators, however, and if the types are always different, it is sometimes difficult to generate reference curves. In this
case it is also possible to compare the coils of a stator amongst each other. Here it is assumed that the surge
curves of the coils (e.g. of the 3 phases of a stator) are the same, in order to be able to compare them to each
other.
As soon as this option has been switched on, the connections of up to 6 coils can be determined.
At a stator with e.g. 3 phases you would for example enter the connections of the 3 phases as follows.
1 2 3 4 5 6
In this example you would enter the test connections as follows:

coil 1 = 1 and 4
coil 2 = 2 and 5
coil 3 = 3 and 6
Compare coils
Owing to the winding / pull-in technique (which sometimes leads to an asymmetrical local position of the phases in
the stator), the surge curves can have slightly different characteristics. It is thus possible to additionally switch star
points by means of the relays in the tester. Therefore the coils are connected to each other during the test and the
curves are more similar.
The operator must try these possibilities from case to case.
The input at “Star” is also a clamp number series or a name series.
Example: If, in the upper picture, the clamps 4, 5 and 6 are to be connected to each other during the test, you need
to enter at Star: 4,5,6.
Cancel in case of “no go”

For every surge test step you can enter, whether the complete test is to be interrupted in case of a no go result.
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3.3.3 Enter test voltage
Before the first measuring for the record of the reference curve is started, the test voltage needs to be entered.
Enter voltage to:
Enter number of shots
To do so you can use the small “up” and “down” buttons right of the voltage value. The voltage can also be entered
via the keyboard.
It is usually tested with a constant voltage at all surge test steps. That means, the fields "Voltage from:" and
"Voltage to:" contain the same value. It is, however, also possible to drive a voltage ramp, in several steps. In this
case, the smalles value is in the field "Voltage from:" and the largest voltage value in the field "Voltage to:". This
voltage ramp is especially for future evaluation methods; it can, however, already be used today with the
correlation evaluation method. Especially in case of a ramp drice of the voltage, in addition the indications voltage
step and number of shots are necessary. In the standard case, i.e. if the fields "Voltage from:" and "Voltage to:"
contain the same value, the voltage level refers to the nominal voltage of the motor that is to be tested. In case of
a nominal voltage of 400V ... 600V, the voltage should be set to 2000V ... 3000V.
The level needs to be set by the operator according to the quality requirements of the company. It is also
determined by the purpose of the motor. Motors that are operated on frequency converters should be tested with a
higher voltage than motors that are “only” connected to standard supply (line voltage).
In case the stator is to be put under harder stress, it is possible to not only do one surge test in the test step but
for example to stress the stator with e.g. 10 surge tests in quick succession. As soon as one of these tests turns
out to be “bad”, the result is no go.
A large number of surge tests (also called shots), increases the test time per test step accordingly. On the other
hand, a test with more than one shot is more sensitive, because repeated impulse voltage stress on the coil makes
it is easier to detect insulation faults that are hard to be measured.
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3.3.4 Enter test voltage
During the test, it is also possible to increase the voltage continuously. In this case you start with a beginning
voltage and increase the voltage until the final voltage is reached. The tester will then, on the basis of the number
of shots, divide the range into the respective voltage steps.
Example: Voltage from: 1000V

Voltage up to: 2000V
Shots: 10
The tester calculates a step width of 111V
It is also possible to pre-set the voltage steps. In this case the tester will calculate automatically the necessary
number of shots.
Enter "test voltage from"
Enter "test voltage up to"
Enter number of shots
The voltage is usually always entered in the input field "Voltage to". As soon as the value "Voltage from" is different
to that value, this will make the automatic voltage increase.
In order to be able to test with only one voltage, it is necessary to enter both values the same. As soon as the
values are equal and the "Voltage to" - value is changed, this value will automatically be taken over to the "Voltage
from" - value by the tester.
What can the voltage ramp be used for?

It can be detected automatically up to which voltage level the insulation can be stressed.
If the tester has the partial discharge test integrated, this ramp is necessary for the execution of the measurement.
Attention: If more than one shot is entered, automatically always the worst value of the deviation is stored and
indicated at the end.
Example: If, in case of three shots, there are these deviations: 1.5%, 2.3% and 1.8%, 2.3% is indicated and
compared with the allowed tolerance value.
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3.3.5 Determine the optimum display of the reference curve
In order to ensure that the tester can supply a safe evaluation, the surge curve should have an excursion as high as
possible and the oscillation should be visible for about 2 – 4 cycles on the screen.
Amplitude / Time basis

By adjusting the amplitude and the time basis with the mouse, it is possible to optimize the display.
It is easier, however, to use the automatic scaling.
Automatic scaling
When you click on it with the mouse, a small hook will appear in the small case. With the mouse, you now you click
on the Start button.
During the measuring, the test cover must be closed.
Activate automatic scaling
Start measurement
Now the tester automatically detects a favorable setting of the time base and of the amplitude. The picture above
shows a favorable setting.
The pictures below show a bad setting.
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3.3.6 Define evaluation methods
After a good setting has been found, the evaluation criteria for the automatic analysis are determined.
Marking line 1
Marking line 2
Evaluation ranges
Activate evaluation methods
Tolerance band
The tolerance band evaluation creates a tolerances band (similar to a tube) around the reference curve. As soon as
the surge curve of a tested stator leaves this tolerance band, there is an error, which will lead to a “no go” result.
Correlation
The correlation is a mathematical similarity calculation between the reference curve an the curve measured. The
correlation evaluation is divided into two areas, which makes the evaluation very strict.
The first evaluation areas is between marking line 1 and 2.
The second evaluation area is between marking line 2 and the right margin of the display window.
If possible, the correlation should always be activated because it is very meaningful.

Since the correlation for both evaluation ranges is calculated separately, two percentage values are indicated.
In the first evaluation area, the correlation is not as “sharp” in the evaluation. Therefore the second evaluation area
is of great importance. For a good analysis, approx. 2-4 oscillations should be visible. The second yellow marking
line should possibly be at the end of the charging curve. The oscillation area starts after the charging curve.
The evaluation in the second area takes place from the second yellow
marking line to the edge of the screen.
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Frequency
The frequency detects the differences in the zero crossings between the reference curve and the curve measured.
Attenuation
The attenuation determination detects the decay of the surge curve in comparison to the reference curve.
This method is a very good supplement to the correlation method and should, if possible, also be activated.
Discharge
The discharge determination detects the discharge peaks within the first evaluation area. The sum of the discharge
peaks is determined.
In order to enable a certain dispersion around the measured surge curve, it is necessary to pre-set the allowed
tolerances / limit values in addition to every activated evaluation method.
The fields right of the activating switches serve for entering the tolerances.
Determine tolerances
Individual results with percentage

divergence
Total result
go = green
no go = red
Now the tolerances for the various activated evaluation methods must be determined. The determination is done
after the criterion that possibly every fault is detected, however all good specimen are tested a go.
If the tolerance is set too narrow, also good specimen will be evaluated as bad and vice versa.
In order to determine the tolerance limits, it is also possible to specifically generate certain faults at a stator and
then determine the tolerance in a way that these faults are detected.
A wire loop is for example a very good aid. This loop can easily be put to the desired points in the
stator or into the slots in order to simulate a short.
In addition to the tolerances it is also always necessary to determine evaluation areas in which the evaluations are
to be done.
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evaluation area 2
evaluation area 1
The evaluations are now done as follows:

Tolerance band evaluation area 1+2
Correlation part 1 evaluation area 1
Correlation part 2 evaluation area 2
Frequency evaluation area 1+2
Attenuation evaluation area 1+2
Discharge evaluation area 1
In the first evaluation area, the evaluation is not very expressive. Therefore, the second evaluation area is of great
importance. For a good analysis, approx. 2-4 oscillations should be visible. The second yellow marking line should
possibly be at the end of the charging curve. The oscillation area starts after the charging curve.
The evaluation in the second area takes place from the second yellow marking line to the edge of the screen.
By activating the Start button it is now already possible to do an automatic evaluation. To do so, it is,
however, necessary to store the reference curve before hand.
The percentage divergence and the total result will be shown on the display window
Start measuring with evaluation
Exit test process in case of no go
Activate this switch if, in case of no go of the test step, the complete test process is to be stopped. Via mouse click
a small hook is placed in the small box.
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3.3.7 Store reference curve
After a good setting has been found, the references curve is to be stored.
To do so activate the store button.
Store reference curve
Delete reference curve
In case no reference curve existed so far, the current measuring will become the reference curve.
In case there already exists a curve, the following picture appears:
Display of the number of

reference curves, that form the
average
Store reference curve
Add reference curve

(form average)
Store reference curve into a file
Store
By activating the Store button, the surge curve that has just been measured becomes the new reference curve.
Add
By activating the Add button, the surge curve that has just been measured will be added to the existing reference
curve by forming the average.
The advantage of this references generating technique is that you are not dependent on only one reference
oscillation of one specimen but you can form the average out of various specimen of one type and define it as
reference setting. This way, after some time, a reference curve for this testing type will be formed, which exists of
the characteristic curves of various specimen and thus covers a wide band of production tolerances.
The window “Average” indicates how many reference curves have already been included in forming the average.
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Add. file
By activating the control box Add. file , followed by activating the Store button, the oscillation curve will be stored
into a file. This file could be read in and edited by another program, e.g. EXCEL. The file name is:
c:\schleich\surgeref.dat. The numbers are stored as integer values in the range between -127 ... +128.
Delete
If, by experimenting, a false reference curve was generated, the reference curve can be deleted with the button
Delete . Now a new reference curve must be generated.
Especially in the beginning, when you familiarize yourself with the surge test, this function is used very often. Also
during production it is possible that, owing to a strong production control, it is necessary to generate a new
reference curve. If this cannot be reached by averaging, the reference curve must be deleted and newly generated.
3.3.8 Specific optimization of the setting
Some cases may ask for a specific optimization of the measurement. Should this be the case, activate the button
Advanced .
Specific optimizations
Hint
Picture file
Charge time of surge capacitor
Discharge time of specimen
Marker positions
Set error ouputs
End input
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Hint
It is possible to show a hint message before every test. In this case, the test is stopped at this point and the tester
waits for a reaction of the operator.
Picture file
In addition to a text display (or instead of a text display), it is possible to indicate a graphic. This photograph or
drawing is read in at a PC with a scanner and stored in the form of a file. This file should be copied onto the hard
disk of the testing device into the sub-directory c:\Schleich\Bilder\ . Here the name of the file is to be entered. The
file can be existant as BMP-, JPG-, or GIF-format.
Charging time
After every surge test, a charging of the surge capacitor in the surge tester takes place.
In case of great inductivity of the specimen or in case of great capacity of the surge capacitor it might be necessary
to wait for a longer charging time in milliseconds before the next surge impulse takes place
In the tester, the standard charging time is firmly set. However, it can be changed by entering a charging time.
This time can be entered positive in order to increased the charging time.
This time can be entered negative in order to reduce the charging time.
Attention: reducing the charging time makes the test process faster. However, too strong a reduction can
result in measuring errors.
Discharging time
Between the various test steps, the specimen is discharged in order to attain clear starting conditions for the
following test. In the tester, this standard discharging time is firmly set. However, it can be changed by entering a
discharging time.
This time can be entered positive in order to increase the discharging time.
This time can be entered negative in order to reduce the discharging time.
Marker positions
The two yellow, vertical marking lines are normally adjusted with the mouse. To do so, you move the mouse arrow
over the marking line, keep the left mouse button pressed and then move the line with the mouse. If you let go of
the mouse button, the line will stay at this position.
The marker positions digitally display the position of the marking lines. Instead of using the mouse, the positions
can also be changed digitally.
Error output (option)

In case of error, via this input it is possible to switch a digital output at the tester. For this application the tester
must put free outputs at disposal (they usually need to be ordered separately).
The output is entered as a number. In the schematics the outputs are numbered (e.g. 149). If this output is to be
switched on in case of error, the number 149 needs to be entered.
If several outputs are to be switched on in case of error, it is necessary to enter several outputs. The numbers are
separated by commas (e.g. 149, 172, 164).
The ouputs stay switched on until a new test process starts.
At standard testers, this input doesn't exist.
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3.4 Process further test steps
In case more than one surge test step is to be done, activate the button List .
Process further test steps
This list serves to select a further test step in order to process it after this.
It is also possible to generate new test steps. A new test step surge test is generated (and stored later) by clicking
on the last line (free line) with the mouse.
The last line is always empty and serves for generating new test steps.
Button OK.
The selection of an existing or new test step is confirmed and the program returns to the recording program. All
parameters that are now being determined will only be valid for this test step.
Button Cancel
The selection of a test step is terminated without a change.
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Button Copy
In order to simplify the generation of reference curves it is possible to copy test steps that are already existing. In
this case, first the test step that is to be copied is marked (mouseclick on the test step, so that it turns blue) and
then the button Copy is activated.
This way the test step will be stored temporarily.
With the button Insert it is then possible to insert all settings of the test step out of the temporary storage
between two other test steps as a new test step.
With the button Overwrite it is then possible to take over all settings of a test step out of the temporary storage
into a different test step.
Button Delete
This command serves to delete a test step.
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3.5 Print
With this command it is possible to print out the reference curve and the currently measured curves.
Print oscillation curve
It is of course necessary to determine a printer with the Windows system control.
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3.6 Detail indication surge test upon test process
This command serves to indicate the measuring results after a test in detail.
For activating the details, the mouse pointer must be on the according test step (e.g. surge test 2-3) and then the
right mouse button must be activated.
Indicate details of the measuring
After activating the command graphics, the graphic display of the surge curve of the selected test step appears.
After activating the command measuring values, the display of the individual measuring values of the selected test
step appears.
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4. Insulation resistance test
4.1 Theory insulation resistance test
The insulation resistance test takes place under theoretical observation at an RC element. The RC element is the
idealized form of the conditions at the specimen.
Why? The specimen has an insulation resistance between the two test points. This is the resistance Riso. This
resistance is usually very high, some 100Mohm and higher. The specimen also has a capacity between the two test
points. This capacity is either generated between the windings that are to be tested or from the winding to the core.
Between the winding it is usually smaller than from the winding to the core. Capacities develop between insulated
metal surfaces. The larger the surface or the smaller the distance of the metal surfaces, the higher the capacity. In
the stator, the windings are one metal surface and the core is the other. The larger the stator (model), the larger
the surfaces and thus the capacity.
If the high voltage test is done with AC, there is a high capacitive charge exchange current in the stator (RC
element). This capacitive charge exchange current is usually much higher than the leakage current owing to the
ohmic resistance Riso (because this is extremely high-ohmic). This means that, through the capacitor, the
continuously flowing charge exchange current (owing to AC) overlaps the fault current that is actually to be tested.
The capacitive charge exchange current is no fault current, but a current based on the physical laws that is always
existent and no quality feature of the stator. Certainly the current must not be to high, however it is not a good
statement on the quality of the insulation.
With the high voltage test DC the charge exchange current can be avoided. Weaker fault effects are thus
emphasized better.
The following equivalent circuit diagram of the insulation system of the motor serves for a better understanding of
the context at the insulation resistance test. On the left side, the graphics show the motor schematically. The motor
consists of windings and the insulation system to the frame. The equivalent circuit diagram of the insulation system
consists of a resistance and a capacitor. The capacity results from the physical and mechanical conditions at the
motor described above. The resistance is a dimension figure for the insulation quality. It is in a range of several 100
MegaOhms. It is important to understand the equivalent circuit diagram, because otherwise it is not possible to set
the insulation resistance test correctly.
Riso
C
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The following picture shows the electrical test conditions during the insulation resistance test with DC.
On the left side you can see the equivalent circuit diagram. The test voltage is connected via the capacitor and via
the resistance. On the upper right of the graphics the voltage course is indicated. The test voltage increases in the
form of a ramp. After the test voltage has increased to the desired level, it stays at a constant level at the specimen
for a certain time. Under the voltage course, the current courses during the test are indicated.
The first current course shows the current in the capacitor. Here you can see that during the increase of the voltage
the current flow in the capacitor is at a constant level. As soon as the voltage no longer changes, the current in the
capacitor also goes back to zero.
The second current course shows the current in resistance. Here you can see that during the increase of the voltage
the current flow continues to increase in the resistance. As soon as the voltage no longer changes, the current flow
stays.
The third current course shows the addition of both currents. This current course is measured during the insulation
resistance test at the motor. It thus consists, like described above, of the two partial currents of the capacitor and
the resistance. Of course, the observation via the equivalent circuit diagram is a theoretical observation. In praxis,
however, the current course shows a very similar wave form.
IDC U, I U
UDC
IC IR
IC
t
IR
t
Riso
C
t
IDC
In order to obtain good measure results, it is very important to make optimum use of the adjustment features of
the insulation resistance test. It is crucial to set the current limit values during the test process optimally. In order
to receive the best possible result, the maximum allowed current for the time of the ramp and the time after can be
set separately.
IDC U, I U
UDC
IC IR
t
Riso
C
IDC
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The setting should be chosen as sensitive as possible. This way the tester can react to disruptive breakdowns, that
can occur during the insulation resistance test, fast and the test can be interrupted.
The following picture shows a test process with a disruptive breakdown during the increase of the high voltage. A
disruptive breakdown can be recognized where, in addition to the current through the resistance and the capacitor,
there is also a current in the lightning of the disruptive breakdown.
IDC U, I
UDC U
IC IF IR
t
IF
Riso
C
IDC
The following picture shows a test process with a disruptive breakdown in the time where the high voltage no longer
changes.
IDC U, I
UDC U
IC IF IR
t
Riso
C IF
IDC
It is important to understand the individual current courses during the insulation resistance test correctly. In order
to be able to set the insulation resistance test optimally, the tester can indicate the graphical course of voltage and
current, as it was during the test, after the test. In principle, the current courses are in praxis similar to the theory.
However, they can only be understood and interpreted correctly if the theoretical current courses are 100% clear.
As mentioned above, the correct setting of the insulation resistance test is very important. Otherwise you will not be
able to find the faults that you want to find.
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4.2 Input of set values
Since the surge tester is equipped with a DC voltage source, this can also serve as a source for an insulation
resistance test with DC high voltage.
The test step is generated the same way as a resistance test step. The following inputs are possible:
Name
The name is the most important input of a test step. In case no name is entered, the test step, even if maybe set
values are entered, the test step will not be executed.
This means the name serves as complete activation of the individual test step.
The name can be a text of up to 40 digits. During the test this text appears also as the name of the test step on the
screen.
Voltage
The voltage indicates the level of the desired test voltage.
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Test connection 1 / 2
This input serves to determine between which connections of the specimen the voltage is to be connected.
1 2 3 4 5 6
K1
Tester
If the insulation is to be tested between 2 coils, you need to enter, for example, at test connection 1: 1,4 and
at test connection 2: 2,5 . In case of this input, the tester internally connects automatically the coil connections 1
and 4 as well as 2 and 5. During the test, the test voltage is put between clamps 1+4 and 2+5 .
If the insulation is to be tested between 1 or several coils to the core, you need to enter, for example, at test
connection 1: 1,4 and at test connection 2: K1. During the test, the test voltage is put between clamps 1+4 and
the core.
If the coils are to be tested at the same time against the core, your need to enter at test connection 1: 1,2,3,4,5,6.
In this case, all coil connections are internally connected with each other in the tester and the test voltageis applied
between the coils and the core.
Special case: tester with special feed control [almost never ordered]
1 2 3 4 5 6
K1 K2
Tester
In this special case (needs to be ordered separately), the feed control is done via two isolated core connection
points (K1 and K2). You need to enter for test connection 2: K1 and for the feed control connection 1: K2.
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Testing time
The testing time determines for how long the voltage is to be connected to the specimen.
Ramp time
The insulation test voltage is normally connected to the specimen in the form of a rising voltage ramp. This makes
sense, because otherwise the capacity of the specimen (capacity e.g. from the winding to the core) would cause a
very strong charging current surge.
Although a higher charging current is flowing during the continuous increase of the voltage than after reaching the
test voltage, this current can be decreased during the charging period (see also the following picture). Ramp time is
the range where the voltage increases.
Imax1
This is the maximum allowed current during the running up of the test voltage. The value must not be set too high.
It should be detected in experiments. For the experiments, the graphical indication can be ideally used. The yellow
marking in the graphical display can be moved with the mouse. Before doing this it is absolutely necessary to
activate ⌧ Edit via mouse click, otherwise the yellow lines can not be moved with the mouse.
Test time Imax1

This is the time during which the maximum allowed current Imax1 is allowed. This time should be somewhat longer
than the ramp time, because, upon reaching the final test voltage, the current doesn’t immediately jump onto the
low value (see picture below).
If the setting has not been chosen to an optimum, it is possible that during the determination of the resistance a
measuring error occurs. The determination of the resistance takes place in the area right of the vertical yellow line.
For the determination of the resistance, the current in this area is additionally averaged. If the test time Imax1 was
chosen too short, part of the falling current can go into the averaging and thus produce a measure error.
Imax2
This is the maximum allowed current after the starting phase of the test voltage.
Imin
The current Imin must be exceeded during the test. By measuring a minimum current it can be seen that the
specimen is connected to the test voltage. If the minimum current doesn’t flow it is possible that the specimen is
not connected correctly.
Especially in an automatic test system, the minimum current should be set to an optimum. The monitoring of the
minimum current ensures that during the test the high voltage was definitively connected correctly to the
specimen.
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Switching off / only valid for special cases (not used for standard applications)
In case the voltage is not only to be increased in one step but in various steps after each other, this switch can be
activated. This enables that the voltage is not switched off at the end of the test step. In the next insulation
resistance test step it is thus possible, referring to this voltage, to increase to the voltage in the next step etc..
Exit total test if the result of this test step is “no go”
In case a fault has been detected at the specimen during a test step, it might sometimes make sense to end further
testing. In order to exit you need to enter a j for yes. The setting is n for no.
0 = continue to test in case of “no go”
1 = end testing
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4.3 Detail indication
With the detail indication it is possible to graphically display the measuring values after an insulation test with DC.
You will get the detail indication after a test by clicking on the insulation test step with the right mouse button
followed by choosing the command Graphics.
After activating the command Graphics, the following graphic chart will be displayed:
Current limit: Imax 1
Testing time: Imax 1
Current course
Voltage course
Current limit: Imax 2
Current limit: Imin
On the left side of the screen, the list of measured values is shown. By pulling the scroll bar it is also possible to
view the values with a number higher than 25.
On the right side of the screen you can see the course of the voltage and of the current during the test in a graphic
chart. The voltage shows a rising ramp for a time of 0.5 sec. During the voltage increase the current is also higher
than after this time, because the capacity of the specimen is being charged.
The time mark (vertically dashed line) is positioned in a way that before the time mark a higher limit current is
allowed than after the mark.
As soon as the current exceeds one of the limit currents, the test process switches off automatically.
During a test there will be a lot of measuring values. In order to show the graphic chart a lot less measuring values
are necessary. For this reason only every 20th measuring value is indicated (standard). This can have a small
disadvantage if for example a short pinpoint is on the current. This pinpoint could be between two indication points
so that they could not be seen on the graphic chart. In case this pin is also visible, the input “number of
intermediate values” would have to be set to 1.
In the tester, the pinpoint of the current is, of course, measured and if it exceeds the limit current the
test will be stopped immediately.
Basically, the graphics of the current always indicates the peak value. The average of the current Iavg is drastically
lower. The low average is considered for the calculation of the insulation resistance.
Please note: the average can partly be significantly lower than the peak value indicated in the graphics.
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5. Partial discharge test
5.1 Theory partial discharge test
The insulation resistance test takes place together with the high voltage test between parts of the winding or
between the winding to the core.
The partial discharge test serves for detecting partial discharge processes that occur in a faulty winding.
For a better understanding of the processes, below please find some information on the insulation system of the
stator. As equivalent circuit diagram, the insulation system shows a capacitor. One board of the capacitor is for
example the winding and the other board is the frame of the stator.
Under ideal conditions, the insulator is placed between the boards completely even. This would be the case, if there
was a piece of insulating material between the boards. In the stator, however, the insulator between the boards is
not very homogenous. The insulator between the wires or in the slot insulation has e.g. air locks and the winding
parts are insulated from each other sometimes far and sometimes not so far. The insulation system can possibly be
disturbed so much that for example a wire of the winding directly touches the core.
In case of a high voltage test with AC or DC, at this point there would be most likely a disruptive breakdown. The
following pictures give examples of insulation faults.
In case of
modern insulations on the Cu-wire, however, it is possible that the enamel on the wire withstands a high voltage
test. In this case, the fault would not be detected before the customer receives the part.
With the partial discharge test it is possible to detect these faults automatically with a high chance.
At an insulation test with high voltage AC, the partial discharge effects occur beginning at a certain voltage level.
There will be partial disruptive breakdown at the faulty point of the insulation. Opposite to a total disruptive
breakdown, the partial disruptive breakdown doesn’t lead to a considerable increase of the leakage current.
Volle Entladung / The partial disruptive breakdown can be

Teilentladung / PD
Durchschlag heard. However, it can also be so weak that
it is neither heard nor seen.
Partial disruptive breakdown means that a
part of the insulator and not the complete
distance of the insulation has a disruptive
breakdown.
Insulation
Insulation
Isolation
Isolation
The partial disruptive breakdown occurs,

because there is a strong concentration of
the field and the insulation can not
withstand this stress. This is e.g. possible in
the small air gap between the wire and the
core (see pictures above) – however, the
enamel on the wire protects against a total
disruptive breakdown.
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The partial discharge test is done parallel to the high voltage test. Either the voltage is continuously increased until
the partial discharge starts or, at a pre-set high voltage, it is measured whether there is a partial discharge or not.
At the high voltage test, the partial discharge begins at a certain voltage level.
It occurs in both the negative and the

U positive half wave of the high voltage.
It is crucial that a certain voltage (the

partial discharge starting voltage) is
exceeded. As soon as this happens, the
partial discharge starts.
Every specimen has a has a typical

t voltage level where a partial discharge
(PD) starts. The voltage level, where the
PD starts is called starting voltage. In
case of a further (often only small)
increase of the voltage over the starting
voltage, the PD increases further to a
considerable extent.
In order to be able to make this effect clear, the software has a special display feature. On the following picture you
can see the visualizing.
The “oscilloscope” indicates the intensity of the PD.

The intensity of the PD is also indicated via two numerical values.
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Explanation of the oscilloscope picture:

The picture shows two areas with PD. The first area corresponds to the first half wave of the sinus of the high
voltage and the second corresponds to the second half wave.
Owing to the respective filter, however, not the sinus wave is indicated on the monitor but only the occurring
partial discharge impulses.
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5.2 Settings for partial discharge test
The partial discharge test is done parallel to the high voltage test. The PD setting parameters are therefore also
included in the menu for the high voltage settings.
The setting of the partial discharge must be detected by experimenting. The specimen is connected and the partial
discharge test is activated.
Now the partial discharge test is started in continuous operation (mouse arrow to PD test step, click right mouse
button and select continuous operation). Now the following picture appears:
It shows the PD with connected test voltage. At testers with manual voltage adjustment, now the voltage can be
adjusted manually. At testers with automatic adjustment, the voltage is adjusted via the two up / down buttons.
The PD is indicated as PD peak (PD peak value) and PD sum (PD sum value). Later, at the automatic evaluation,
these two numerical values are determined as upper limit values.
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The process for detecting the PD starting voltage is as follows:

The first test is done with a motor as good as possible. The test is started with a low high voltage. You can see no
PD on the screen.
If still PD can be seen, the specimen is either defective or there is a strong irridation from an external source of
interference to the stator (e.g. frequency converter etc.).
Now, the voltage is increased until individual PD peaks occur. If this PD occurs at approx. 1200V and higher, this is
normal and the stator is most likely a good stator. As already described, starting from a certain voltage level there
is a PD at every specimen (also at good stators). Depending on the stator, this voltage is in a range between
approx. 1100V ... 1400V. If the PD already occurs at lower voltages, it is most likely that there is a fault at the
stator.
In this manual it is not possible to make a 100% clear statement about when the PD starts. In order to get a feeling
about what is PD, when it starts, etc., you need to make experiments with good stators and maybe with prepared
bad stators. The necessary experience is similar to the experience for the surge test.
As soon as the limit values of the partial discharge (PD peak and PD sum) have been detected, they can be entered
into the set values for the automatic test process.
If one (or both) values are exceeded during the automatic test, there is a fault at the stator and the test step will be
“no go”.
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Explanation of the display on the screen
As soon as the continuous operation is started, the PD test is activated also. By increasing and decreasing the
voltage, you can check when PD starts.
Please note: It is possible that during the PD test the indication of the current is too high. This is caused by an
effect of the measuring technique, which cannot be avoided. As soon as the PD test is switched off, the indication of
the current is correct again.
Via the button Reset TE-sum max. the maximum

value storage is reset to zero. The maximum value
storage serves for storing the highest ever PD sum
value that occurred during a test. This facilitates
finding the correct PD sum limit value for the input
of set values.
Deleting the maximum value storage is especially
helpful, if during an examination the voltage is
decreased in order to increase it again later on.
Via the regulator “Time of luminescence”, you can
give the graphical display a certain luminescence
effect. This can be useful, if there are only a few PD
impulses. This way, these can be kept on the screen
for a certain time period.
At the end of the experiment, the aim should be to detect the maximum allowed PD sum value and the PD peak
value, in order to be able to enter these two values as limit value in the set value input. Of course, the respective
test voltage is needed.
An optimum use of the PD test is therefore only possible with an automatically adjustable high voltage, because the
PD test voltage is significantly lower than the test voltage at the high voltage test. For changing between the
voltage values, the automatic adjustment is needed.
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6. Setup settings for the surge test
For changing the options of the surge test, it is necessary to call the command Setup Options... . Please also refer
to the programming manual.
After this, you will see the following picture:
Now you need to click on the index card Tests.
Now, the button Set test methods.. needs to be activated.
After this, the seup window for all test methods. Here you need to select the surge test.
At the end, the button Options.. must be activated.
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Further settings / special attachments
⌧ Display surge curves in case of “no go”

Explanation: This option needs to be activated if during the test ins case of “no go” the measured surge
curve is to be indicated with the reference.
⌧ Surge tester with I2C-control

Explanation: This is in important factory setting und must under no circumstances be changed.
⌧ Surge test with adjustable ramp

Explanation: This option needs to be activated in case that during the test it is to be possible that the
voltage can be automatically increased.
(Meaning and function: see chapter Input of Test Voltage)
⌧ Switch clamps invers

Explanation: ???
Max. Volt/Div. ???????
Colors of the surge curves in automatic mode
Double-clicking the color opens the range of colors and it is possible to allocate the desired color for a coil.
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7. Hardware
7.1 Technical Data
Surge test
Scanning frequency WIN : max. 40 MHz
Test voltage : 200 ... 6000V
Energy at 100nF : 1.25 WS (1.25J) at 6KVDC Standard [Berechnung: E=½ x C x U2 ]
Energy at 40nF : 0.72 WS (0.72J) at 6KVDC (special surge capacity please indicate with order)
Energy at 20nF : 0.36 WS (0.36J) at 6KVDC (special surge capacity please indicate with order)
Testable inductivity : >2µH (smaller values are possible on request)
Imax : 400 A (333A)
Impulses per step : 1 ... 1000
Testing time in WIN : min. 0.2 sec. per step
Insulation resistance test

Measuring range : 0 ... 3mA
Resolution : 1µA
Test voltage : 200 .... 6000V DC
max. current : 3mA
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7.2 Pin assignment of plug at surge draw-out unit
pin assignment of the SUB-D control plug X1:
1 24V DC (external supply for the surge tester)

2 Surge on (release / jumper to 3)
3 Surge on (release)
4 free
5 free
6 I2C bus pulse
7 I2C Data from PC
8 free
9 free
10 measuring range D0
11 measuring range D1
12 I2C Data to PC
13 free
14 GND 24V
15 switch on high voltage in surge tester (apply +24V to this connection)
16 measure high voltage in surge tester (apply +24V to this connection)
17 start surge tester (apply +24V to this connection)
18 high voltage switch-over for special additional capacitor box (option)
19 discharge surge tester (apply +24V to this connection)
20 free
21 Insulation resistance test (apply +24V to this connection)
22 Capacitor switch-over for special additional capacitor box (option)
23 Capacitor switch-over for special additional capacitor box (option)
24 free
25 free
Pin assignment of he high voltage sockets:
high voltage socket GND : ground of surge voltage or of insulation test voltage
high voltage socket HV out : + (plus) of surge voltage or + of insulation test voltage
Pin assignment of BNC plugs (coaxial cable plug):
BNC plug trigger : control signal for starting the measuring on the oscilloscope card
BNC plug signal : measuring signal output of the surge curve
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8. Subject index
A L
Attention 4, 6, 30 Liability 9
Attenuation 26, 27
M
C
Marker positions 30
Charging time 30
connection configuration 18 O
connection possibilities 10
Copyright 9 oscilloscope 12, 52
Correlation 25, 27
P
D
Pin assignment 52
Detail indication 34, 42 Process further test steps 31
Discharge 26, 27 Prüfzeit 40
discharging time 30
dispersion 26 R
draw-out unit 52
reference curve 12, 13, 14, 15, 19, 21, 22, 24,
E 25, 26, 27, 28, 33
relay matrix 10
Error output 30
evaluation methods 13, 15, 22, 25, 26 S
F safety 4, 5, 6, 8
Safety 4
Frequency 26, 27 Set values 14
SUB-D control plug 52
G surge test 11, 12, 14, 15, 22, 30, 31, 34, 43,
49
General information 9, 11 Surge test 11, 51
Generate new test step 15
T
H
Technical Data 51
Hardware 51 Test connection 39
test connections 10, 15, 17, 19, 21
I Tolerance band 25, 27
Imax1 40 V
Imax2 40
inductivity 12, 30, 51 VDE 0104 6, 8
Input of values 38 voltage ramp 22, 23, 40
Insulation resistance test 35, 51, 52
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Notes:
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9. Annex
Written confirmation that the operating manual has been read carefully and understood.
Person (Name) Department Date Signature
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SCHLEICH - EN - Bedienungsanleitung SurgeWin

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SCHLEICH - EN - Bedienungsanleitung SurgeWin

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Operating Manual

of the surge tester

for the devices

last revision : 17.12.01

date of print-out : 8/19/2014

2. Configuration of the test connections 10

4. Insulation resistance test 35

5. Partial discharge test 43

6. Setup settings for the surge test 49

1.1 Safety symbol

1.3 Regulations for safety at work

1.4 Important information for users of high voltage testing equipment

Caution! High voltage!

2) Working with test pistols

3) Working with test covers

1.7 General information on this manual

2. Configuration of the test connections

Below please find examples of connection possibilities:

All shown connection possibilities are imaginable.

group 1 clamps 1, 2 and 3

3.1 General information on the surge test

The surge test is a comparative test.

Picture: typical voltage curve upon the surge test

3.2 Set values

3.3 Generate new test step (or change)

We recommend the following procedure:

1. Enter name of test step

3.3.1 Enter name of test step

activate button „Connections“

Now the following picture appears:

Name of test step

3.3.2 Determine test connections

activate button „Connections“

Now the following picture appears:

Enter beginning connection of the

Enter end connection of the coil

The following picture shows a typical connection configuration of a stator:

Also test inverse

Option: Test also invers

Connect core ground during the test

Option: “Connect frame during

Compare coils with each other

In this example you would enter the test connections as follows:

The operator must try these possibilities from case to case.

The input at “Star” is also a clamp number series or a name series.

Cancel in case of “no go”

3.3.3 Enter test voltage

Enter voltage to:

Enter number of shots

3.3.4 Enter test voltage

Example: Voltage from: 1000V

Enter "test voltage from"

Enter "test voltage up to"

Enter number of shots

What can the voltage ramp be used for?

3.3.5 Determine the optimum display of the reference curve

Amplitude / Time basis

During the measuring, the test cover must be closed.

Activate automatic scaling

3.3.6 Define evaluation methods

Activate evaluation methods

If possible, the correlation should always be activated because it is very meaningful.

Individual results with percentage