Baker Instrument Company AWA Surge Test pass/fail criteria:

When performing a surge or surge comparison test on three phase motors, you are
evaluating the integrity of the coils inside the motor. There are certain motors that will,
by design, show a mismatch when the phase signatures are compared to each other.

Why? Because there are two common winding types for three phase motors.

Lap winding: Means that all coils in the motor span the same number of slots, same
amount of turns and the same shape. There will be the same amount of coils as slots.
High capacity motors are usually lap wound. These motors are most often wound by
craftsmen, since it is can be difficult to automate this process. Good windings surge
signatures will coincide very closely.

These types of electric motors are most often built with rectangular wire, which then
become the coils. These are almost always used in medium and high voltage motors.
(Example: 2300 Vac, 200 H.P. and higher).

High capacity motors of this type are most likely to be found in power generation/heavy
industrial processes such as mills and foundries/electric propulsion such as locomotives,
mining equipment, maritime, and large irrigation and water diversion projects.

Concentric winding: May have 1, 2, 3 or more different spans, they may have
different number of turns per coil, and there may be the same, one-half, or two-thirds the
number of coils as slots. These motors are wound by machine. This can influence the
phase signatures. Good surge signatures may have quite noticeable separation.

Concentric windings are more often found in lower capacity applications. There are many
reasons, but two of the primary ones are: It is much easier to automate the process, and
the lower capacity requirement allows use of round wire. This round magnet wire is
much easier to insert into the slots/teeth of the stator. Since round wire is designed into
these motors, it almost always means the machines are rated for 600 Vac or less.

Motors of this type are more often found in lower capacity applications, driving air
compressors, water treatment, air handling, machine tools, etc, etc. While no rule exists
for type, smaller motors are mass-produced which leads to machine assembly. In the field
there is a significant chance that sub - 600 Vac, 100 H.P machines could be concentric
wound.

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Discussion of AWA Surge Test pass/fail criteria:
There are 4 criteria available to configure the pass/fail parameters. Each test has its
particular strength, and used together give a high degree of confidence regarding turn-to-
turn insulation integrity.

L-L EAR % (Line to Line Error Area Ratio)

P-P EAR % (Pulse to Pulse Error Area Ratio)
Zero Crossing %
Test-Ref EAR %

L-L EAR %: A method of mathematically comparing the surge wave from three
phase windings against each other. The reported value is seen only after the conclusion of
the test sequence. The method is extremely sensitive to differences in the waves. The
waves are the surge impedances of the tested windings compared to each other. Can be
used between 500V and 30,000 volts. There are several performance considerations,
which could lead to mis-interpretation of surge results.

1) Rotor position. If possible the keyway slot should be in the same position for each
test. Since this is usually a problem when testing motors in service a higher %
pass/fail value would be required.
2) Winding configuration, i.e. Lap wound or Concentric wound.
3) Rotor condition, field experience shows that grossly damaged rotors can influence
the surge signature.
4) Motor connection, it is important to know if a wye or delta configuration is being
tested.
5) High/low speed dual windings, the untested winding should be jumped out and/or
grounded.
6) Iron condition, moderately-heavily damaged iron laminates can have a noticeable
influence on the surge signatures.
7) Iron saturation, the pulses of current applied by the surge test may create a
hysteresis response in the rotor and stator. Leads to a slow, gradual shift to the left
as more energy is applied to the surge. Eventually may shift the wave out of the
pass/fail window. Could require a higher pass/fail %.

For the above reasons, the L-L EAR % test must be set at an artificially high level for
field use.

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P-P EAR %: A real time method for waveform analysis. It operates while the surge
test is in progress. Uses the error area technique follows. Each pulse applied by the AWA
is digitized. Each successive pulse is mathematically compared to the previous pulse.
Example: To reach a test voltage of 2000V with Step Voltage set at 25 volts/step means
the AWA will take 80 steps from 0V to 2000V. This means the progression is as follows:
0V, 25V, 50V, 75V….1950V, 1975V, 2000V, conclude test. The difference between any
successive pulse, such as 1950V and 1975V is the P-P EAR %.

This method does not have any of the limitations of the L-L EAR %. It is completely
immune to the effect of rotor position, rotor condition, winding configuration, motor
connection, iron condition and saturation.

This test is the most modern method available for assessment of turn-to-turn insulation
integrity using the surge test. It is applicable for test voltages between 1,000V and
30,000V.

Zero Crossing %: A method for looking at the decay of the surge wave, where it
crosses the X-axis. It is applicable between 500V and 30,000V. This method has certain
performance considerations shared with the L-L EAR %, they include:

Iron saturation, the pulses of current applied by the surge test may create a hysteresis
response in the rotor and stator. Leads to a slow, gradual shift to the left as more energy is
applied to the surge. Eventually may shift the wave out of the pass/fail window. Could
require a higher pass/fail %

More zero-crossings appear as test voltage is increased. When test voltage is increased
the applied voltage amplitude becomes great enough to drive extra ringing in the wave-
pattern.

If enough extra, low amplitude zero crossings appear the AWA may conclude the test
with a NESTED FAILURE message. The test should be repeated with the P-P EAR%
turned on, and Zero Crossing % turned off. (As long as the test voltage is at least 1000V)
If the test then passes with turn-to-turn insulation is acceptable.

Test-Ref EAR %
This test is used when multiple motors of the same design and construction must be
tested. It is designed for the motor manufacturing process, and during rewind processes.
It is extremely sensitive to winding and motor condition.

It has performance considerations that mirror those of the L-L EAR %. It uses the same
criteria of the L-L EAR% to determine the mathematical values of the surge waves.
It is capable of great discrimination between successive tests. However, it must be used
with caution in the field for the same reasons as the L-L EAR%. A reference waveform
must be stored into the memory bank before this test can be performed.

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Summary:

FIELD, LAP WINDING

L-L EAR % P-P EAR % Zero Crossing % Test-Ref %
10-30% or Off 5-15% 10-50% or Off Manufacturing

Field, Concentric
L-L EAR % P-P EAR % Zero Crossing % Test-Ref %
35-65% or Off 5-15% 10-50% or Off Manufacturing

Manufacturing
L-L EAR % P-P EAR Zero Crossing% TEST-Ref %
(No Rotor installed) 5-15% 5-20% 5-15%
5-15%

(Rotor installed) P-P EAR Zero Crossing% TEST-Ref %

15-65% 5-15% 10-25% or higher 10-25% or higher