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MCM User Manual

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1. Recommended safety precautions should be followed at all times Both current and voltage transformers can present lethal currents and voltages when their primaries are energized and standard practices i e shorting the secondaries of current transformers and removing voltage transformer fuses must be respected during installation or any subsequent service The unit is designed for operation in a control cabinet with restricted access to the rear terminals and should not be used in any environment where this is not the case MCM should not be used for the purpose of primary protection of electrical equipment Disclaimer Maintenance planning information as well as its timing is issued based on the observations in the field and is approximate and considers the average behavior of different types of equipment Since each piece of equipment and conditions under which it runs may be different actual failure periods may be different Therefore it is recommended that maintenance actions and their timing indicated in the MCMScada Report should be used only as a guide and the indicated abnormalities should be checked and remedied as soon as feasible Product Disposal Statement Customers and third parties who are not member states of the European Union who are in control of the product at the end of its life or at the end of its use are solely responsible for the proper disposal of the product No person firm corporation assoc
2. It is therefore important to ascertain the cause of the alarm at the earliest opportunity 3 4 2 2 Viewing alarm messages An alarm is indicated on the front panel of MCM by the message Alarm followed by a hexadecimal value The bits of the hexadecimal value refer to which alarm is raised Repeatedly pressing the RIGHT or LEFT buttons cycles through a list of all active alarms Please refer to the appendix for a complete list of possible alarm conditions and their remedies The measured physical motor values can be viewed during an alarm by pressing the UP or DOWN buttons This is often useful in determining the reason for an alarm PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 3 4 2 3 24 Fault status indication Status String LED Fault Severity Number LEARN MCM has insufficient data to assess the status of equipment NORMAL 1 Motor is healthy or level of failure is under alarm thresholds WATCH LINE 2 There is a change on the supply voltage to the motor Temporary changes in supply voltage cause this alarm If this alarm is persistent check harmonic levels capacitors isolation of cables motor connector or terminal slackness loose contactors etc WATCH 3 There is a possibility of a load change If the process load LOAD has not been altered deliberately check for leakage valve amp vane adjustment pressure gauge faults manometer dirty filters fans compressors If the process
3. Rx a Tx p uer www Ortesis com MCM uses 2 wire or 4 wire RS422 RS485 communications with optically isolated to 2500V inputs and outputs MCM is configured as a slave device and needs to be addressed before it will communicate over the bus It will support communication rates of up to 19 200 Baud over distances exceeding 1000m but this rate can be degraded if the environment is especially noisy For 2 wire connections each terminal pair Tx Rx and Rx Tx must be connected together on each MCM device In some cases particularly with slow PC hosts that do not release the transmit line rapidly it may be necessary for the MCM device to delay its response This can be achieved by adjusting the value of the menu setting MENU Edit Settings Comm Settings Response Delay In the diagrams given above the terminals marked 0 on each MCM device are connected together and with the 0 terminal on the converter Internally these terminals are connected to the local ground via 100 Q resistors This optional connection is provided in order to have a quality return path for the differential signals which can in some circumstances reduce noise and lead to better communications In cases where the ground quality is adequate this connection can be left unused Similarly terminating resistors between the terminals on the last device in the daisy chain star topologies are not recommended may be used These resistors typically of value 12
4. Section 2 MCM Installation Installing with soft starter systems MCM can be installed with standard soft starter systems provided that they are automatically bypassed immediately after motor start up and during subsequent use Un bypassed soft starter systems can introduce considerable distortion into the current waveforms and thus prevent MCM from modeling the properties of the motor itself If MCM is to be used with such a system it is essential that the maximum current limit of the starter be above the nominal running motor current so that it is bypassed effectively during all normal operation NOTE MCM should never be used on a system that employs soft starters for speed control or other un bypassed uses Please refer to the diagrams in the appendix for details of the connections needed for soft starter systems NOTE Soft starters should always be bypassed 2 8 Installing with inverter drives Using MCM with inverter driven motors requires the same voltage connections specified for line driven systems External Hall effect current sensors must be used with inverter systems as normal current transformers have insufficient bandwidth for use with the range of frequencies obtainable from inverters Please refer to the diagram in the appendix for details of the connections needed for inverter driven systems PS 01 KL 01 REV 00 3 1 Section 3 MCM Use 3 MCM Use Introduction Use of MCM is bot
5. The equipment should not be positioned so that it is difficult to operate the disconnecting device NOTE Please note that in order to function at its full capability MCM requires that the case be connected using a low impedance cable 12 14 AWG cable is recommended directly to a high quality ground via the ground terminal on the power connector If a suitable ground is not provided fault free operation within specifications cannot be guaranteed 2 6 Applying power to the MCM unit 14 Once the motor connections have been made to the rear panel power should be applied to the unit MCM requires between 100 and 240VAC obtained from a single phase neutral and ground At this stage the Power indicator at the left of the front panel will light If this does not occur please check that the correct voltages have been applied Immediately on application of power the LED condition indicators should briefly flash and activity should be seen on the main display The text Initializing followed by a series of dots will appear Initializing After a few seconds the display should indicate that it is in the IDLE mode MCM is now ready for use When using a device for the first time the message Bad flash data Press Clear may be displayed In this case press the CLEAR button several times until the message disappears Once a valid learn mode has been completed this message should not occur again 2 7
6. This is accomplished by holding down the LEFT button while simultaneously either switching on the device power or pressing and releasing the reset button at the rear of the device NOTE The unit must be in the IDLE state before removing the power or pressing the reset button or this procedure will not work The button must remain held down for at least four seconds until the message appears on the display Press Enter for general reset At this point ENTER should be pressed to perform the reset If this does not clear the error it is likely that the MCM device is experiencing a hardware fault and that the unit should be returned for servicing 3 4 9 5 Using the relay output MCM is equipped with two connections on the rear panel internally connected to a low power normally open relay Closure conditions of the relay can be programmed from MENU Edit Settings Password Run settings Relay Threshold Select the desired fault level During MONITOR IMPROVE and UPDATE the relay will become active anytime the fault level rises above the selected relay level and the following message will be displayed Relay active When the relay is active and the previous message displayed pressing the LEFT or RIGHT buttons cycles through the messages Acknowledge Reset relay Pressing the CLEAR button while either of these messages is displayed deactivates the relay Selecting Acknowledge will cause the relay to act
7. are selected so that a temporary change in Motor Status 1 does not cause any change in Motor Status 2 The meaning of each level is summarized in the following table PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 58 Condition Motor Meaning MCM Status Display 2 The frequency of Motor Motor is running OK Status 1 values greater than 1 1 normally does not exceed the first frequency threshold The frequencies of Motor The motor is behaving in Line Status 1 values greater than 2 a manner differing from one and the line changes the reference model exceed the specified This difference may be thresholds due to power line voltage levels not encountered during the learning phase The frequencies of both The motor is behaving in Load Motor Status 1 values greater 3 a manner differing from than 1 and load changes the reference model exceed the specified This difference may be thresholds due to loading conditions not encountered during the learning phase The frequencies of Motor The motor is behaving in Examine Status 1 values greater than 1 4 a manner differing exceed the second frequency significantly from the threshold and the frequencies learned reference of both line and load changes model due to a fault are below their corresponding developing in the motor thresholds and or the systems connected to the motor The frequencies of Motor The motor is behaving in Examine2 Status 1 values
8. interval check the connections cabling baud rate pc ports etc Waveforms of the last data acquired by MCM during data acquisition can be uploaded to the pc for inspection as follows Send the MCM unit to IDLE mode by selecting the Idle command from the Command Selection combo Note that the unit always sends the current data stored in its memory so after any changes to the input conditions it will be necessary to refresh the stored data by sending the unit to CHECK MOTOR mode using the Check Motor command Section 4 Troubleshooting Initiate the upload mode by sending the Take Data command The software will wait 6 seconds and then enable the Upload button Press the Upload button and observe the Data Received text displayed together with the current number of data points The progress bar in the Upload Panel will indicate how much data has been downloaded When sufficient data available press the Cancel Upload button to display the voltage and current waveforms The view can be zoomed using the mouse to define the desired region while holding down the left button Pressing the right button restores the view Voltage and current waveforms corresponding to the same phase are plotted in the same color If the Display calibrated data checkbox is selected the data are scaled according to the device calibration Deselecting this box is sometimes useful to view both the voltage and current waveforms together The following waveforms
9. 2 5 12 Three standard 5A secondary current transformers of appropriate ratings are recommended for current sensing please refer to the appendix at the end of this manual for full transformer specifications The secondary outputs from each transformer should be connected to the corresponding current measurement terminal pairs 131 142 121 122 131 132 on the rear of the MOM unit WARNING If compensation capacitors are employed it is essential that the current transformers be placed between the motor and the capacitor bank so that only the true motor currents are measured Standard 100V 110V and 120V secondary voltage transformers should be used to drop the voltage to usable levels Connections from the secondary outputs of the transformers should be made to the respective voltage measurement terminals Vi V2 Va at the rear of the unit Please refer to the connection diagrams in the appendix at the end of this manual for further details Rear panel connections Connections to the MCM rear panel are given in the following figure Lethal voltages can be present at the voltage and current terminals and it is vitally important that power is removed from both the motor and the MCM unit prior to any connections being changed t WARNING Remove ALL power prior to changing connections Multiple Energy sources present The three motor power voltages should be connected to the corresponding measurement te
10. 300A current working current Display A Nominal Nominal line Edit 20 5 50Hz frequency frequency or most Display 120 Hz common inverter operating frequency Nominal RPM Nominal angular Edit 0 32000 1500 speed of the motor Display rpm Connection Motor connection Edit Star Delta Star type type under normal Display running conditions Motor serial Optional identifier Edit mooo Display Calibration V channel 1 Calibration factors Edit 0 1 1 0 for each input Display 999999 V channel 2 channel sensor Edit 0 1 1 0 Display 999999 V channel 3 Edit 0 1 1 0 Display 999999 channel 1 Edit 0 1 1 0 Display 999999 channel 2 Edit 0 1 1 0 Display 999999 channel 3 Edit 0 1 1 0 Display 999999 PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual acquisition If the current variation exceeds this value the line is considered to be unstable Edit Submenu Description Type Range Default Settings items Value Menu Group Alarm Current Maximum permitted Edit 0 100 20 Thresholds balance current imbalance Display 60 26 Voltage Maximum permitted Edit 0 100 10 balance voltage imbalance Display 50 Voltage range Maximum permitted Edit 0 100 10 voltage upper limit Display 90 as above nominal Max Maximum permitted Edit 0 100 50 Current 6 current upper limit Display 90 as 96 above nominal Low voltage Mini
11. Edit Submenu Description Type Range Default Settings items Value Menu Group Motor Admittance Ratio of RMS current Display N A N A Values to voltage only Phase angle Angle between V Display N A N A and l channels in only degrees q Powerfactor Cosine of phase angle Display N A N A between V4 and l only channels Cos Active power y Cos Display N A N A only Voltage Calculated based on Display N A N A balance 96 NEMA National only Electrical Manufacturers Association definition A measure of imbalance between phases 0 perfect balance Current Calculated based on Display N A N A balance NEMA National only 96 Electrical Manufacturers Association definition A measure of imbalance between phases 0 perfect balance RMS Voltage Measured RMS Display N A N A 1 quantities for each only RMS Voltage input channel Display N A N A 2 only RMS Voltage Display N A N A 3 only RMS Current Display N A N A 1 only RMS Current Display N A N A 2 only PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 60 Edit Submenu Description Type Range Default Settings items Value Menu Group RMS Current Display N A N A 3 only Line Measured line Display N A N A frequency frequency only Phase The observed order Display N A N A ordering of the connections only relative to the V4 input
12. adjust the frequency setting accordingly During IMPROVE UPDATE and MONITOR this requirement is relaxed and the frequency can assume any value within the allowed frequency range NOTE MCM is not suitable for the following applications e f motor supply voltage is changing over 15 in 6 seconds e f motor current is changing over 15 in 6 seconds e DC motors e f motor is driven by an inverter whose chopping frequency is under 2 kHz 3 4 6 Running RESUME and UPDATE 3 4 6 1 Canceling running All the operating modes LEARN IMPROVE MONITOR and UPDATE can be stopped and started at any time without significant effect on monitoring performance by pressing the CLEAR button and providing the correct password if Local Lockout is ON Subsequent restart of MCM can be achieved by selecting RESUME from the main menu which will cause MCM to continue in its incomplete mode at the point of interruption Thus if it is necessary to stop MCM for any reason it can be restarted without affecting any existing data 3 4 6 2 UPDATE At subsequent times it may be desirable to learn a new operating point of the motor This can be done using the UPDATE function This can be reached either 50 3 4 6 5 3 4 7 Section 3 MCM Use from the main menu in IDLE mode or by pressing first the RIGHT and then the ENTER button during MONITOR Updating the internal database When MCM first starts in the MONITOR IMPROVE or UPDA
13. channel Lower case voltage upper case current Harmonic THD 76 Total harmonic Display N A N A Values distortion of the only selected input channel 1 Harmonic Harmonic contents of Display N A N A the selected input only 3 Harmonic channel Display N A N A only 5 Harmonic Display N A N A only 7 Harmonic Display N A N A only 9 Harmonic Display N A N A only 11 Harmonic Display N A N A only 13 Harmonic Display N A N A only Signal Select The input channel Edit V1 V2 V3 la selected for Display 15 l3 harmonic measurements Harmonic calc switch harmonic Edit ON OFF ON calculations On Off Display Comm Device Networking address Edit 1 255 0 Settings address Display Baud rate Communications bit Edit 300 38400 19200 transfer speed Display Section 5 Appendices Edit Submenu Description Type Range Default Settings items Value Menu Group Parity Parity check Edit Even Odd Even Display Data bits Number of bits Edit 7 8 9 8 containing data Display Stop bits Number of bits Edit 1 2 2 indicating end of Display transmitted frame Response Delay in ms before Edit 0 9 0 delay MCM will respond to Display an input command Motor Nominal Nominal motor phase Edit 0 1 230 VAC Settings voltage neutral working Display 200000 voltage VAC Nominal Nominal motor Edit 0 1 30000
14. has been altered deliberately MCM should be updated EXAMINE 1 4 Plan Maintenance There are developing mechanical and or electrical fault s Although the level of the failure is not serious the maintenance should be done in the next planned outage no later than 3 months EXAMINE 2 5 Do Maintenance There are developing mechanical and or electrical fault s Maintenance and corrective action should be performed as soon as possible When monitoring a motor in test mode MONITOR IMPROVE or UPDATE MCM provides a status indication on the right side of the upper display line This consists of one of the items in the table above In addition one of the five LED indicators on the front panel is lit showing the color corresponding to the motor status in the table above As with all grading schemes there is always some overlap between the bands and it is possible for a healthy motor sometimes to indicate a fault severity greater than 1 However in healthy motor systems such false alarms should be transitory and prolonged display of a fault should indicate the need for maintenance Section 3 MCM Use NOTE A prolonged fault indication should always be investigated 3 4 5 Running CHECK MOTOR On first use of MCM and each time any maintenance is performed on the motor it is essential that the motor together with its connections are checked by running the CHECK MOTOR function In this mode MCM performs a short c
15. learn the new voltage supply conditions after which the status will eventually return to normal PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 3 4 9 5 3 4 9 4 40 Load changes Motor status levels associated with changes in the loading conditions occur with the Watch Load Message on the front panel the third orange LED indicator being lit and Motor Status 2 taking a value of 3 They are also temporary in nature but they should be treated more carefully than line changes as some faults developing in motor based systems can cause changes in the loading conditions For instance leakages from pump seals can cause pressure drops which will be interpreted by MCM as changes in the loading conditions Similarly clogging in a pipe or membrane or an increase in the friction of moving parts will be detected as changes in the apparent load It is therefore important to assess the root cause of the load change In certain cases for instance closing or opening a valve or changing a pipe the changes in the loading conditions are intentional and should already be known by the user In such cases the user should send MCM to the UPDATE mode so that it will learn the new loading conditions When no obvious cause can be found it is likely that a fault is indeed developing and the situation should be monitored more carefully Error messages Unlike alarms errors refer to failures of the MCM hardware and software rather
16. on the front panel of the MCM unit and reported by the MCMScada monitoring software are actually the values of the Motor Status 2 parameter Motor Status 1 is not available from the front panel and can only be monitored using the trending plots of MCMScada The LED indicators on the front panel of MCM correspond to the values of Motor Status 2 starting with OK value of 1 on the left and increasing up to Examine 2 value of 5 on the right 3 4 9 2 Changes in line voltages Motor status alarms associated with the changes in the line conditions are indicated by the Watch Line message on the front panel the second yellow LED indicator being lit and Motor Status 2 having the value of 2 They are usually temporary in nature and generally the user does not need to take any action However it is recommended that when this status level occurs the user should at least assess the extent of the change in the line conditions as significant changes in the line voltages and currents may be dangerous to the motor If the line status change is persistent the user should assess the root cause of this change For instance it may be due to a problem in the contactors or for inverter driven motors the settings of the inverter may have been changed In any case if the root cause cannot be remedied easily and quickly and the new voltage supply condition presents no danger to the motor the user has the option to send MCM to the UPDATE mode This will allow MCM to
17. percentage of nominal Low current 96 Minimum acceptable level below which current is considered to be zero for motor not running alarm as percentage of nominal Load threshold 96 Used by the phase ordering algorithm to set the loading threshold If the ratio of actual current to nominal current is more than the value of the Load threshold in then the motor is considered to be working under load and the appropriate phase ordering selected Otherwise the motor is assumed to be unloaded Run Settings Learn The number of data acquisition iterations required for iterations a LEARN period A value between 3000 4000 is recommended Improve The number of data acquisition iterations required for iterations the IMPROVE phase A value between 8000 10000 is recommended Update The number of data acquisition iterations required for iterations an UPDATE phase A value between 1000 2000 is recommended Flash update rate Section 3 MCM Use MCM does not update the flash with new values at each iteration as this could shorten the flash lifetime On the other hand the longer data are stored in volatile memory the greater the potential for data loss if power fails As a compromise the user can set a suitable time measured in complete iterations after which all outstanding data are automatically saved to flash Local lockout When this setting is on passwords have to be supplie
18. to either Artesis or its designated agents if repair is needed Cleaning Clean the display and the keypad periodically using a dry cloth Detergents can damage the device Do not use detergents PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 5 Appendices 5 1 Appendix 1 MCM Error alarm and warning conditions 5 1 1 Error Conditions 50 Format First Byte Minor code Second Byte Error type Error Error type Description Number 0x010000 Memory The dynamic memory manager failed in a request to allocation error allocate a block of memory 0x020000 General error An unexpected or general error occurred 0x040000 Zero division The algorithm attempted to perform a division by zero 0x080000 Flash Write There was an error attempting to write to flash 0x100000 Illegal square root The algorithm attempted to form the square root of a negative number 0x200000 Initialization error Initialization was not properly finished or an error occurred 0x400000 No data error There is no data present 0x800000 Data acquisition An error occurred during data acquisition causing error insufficient data to be acquired 0x01000000 Parameter error An illegal value was calculated for an algorithm parameter 0x02000000 Flash error An attempt to read or write from the flash RAM gave an error indicating a faulty flash The device can only be restarted by removing power and perfo
19. value of the same parameters that are obtained during the learn stage These differences are normalized with respect to their standard deviations obtained during the learn stage Hence the values indicate the number of standard deviations they are away from the average values obtained during the learn stage If they exceed threshold values then an alarm is given The changes in their values are associated with the faults that are developing in the system As an example an isolation problem in winding will affect the parameters associated with resistances Their change will allow MCM to detect the isolation problem at an early stage Though they are primarily used to detect electrical problems they also can indicate mechanical problems as well As an example an imbalance or gear problem would cause dynamic eccentricity in the air gap This eccentricity will cause a change in the induction parameters and therefore in the model parameters By monitoring the changes in these model parameters imbalance can be detected at an early stage This eccentricity eventually affects the bearing eventually leading to its damage Therefore detection of eccentricity at an early stage can prevent further damages The electrical parameters are further classified in two groups E1 internal and E2 external parameters Electrical parameters 1 4 E1 indicate problems associated with rotor stator winding etc while 5 8 E2 indicate electrical supply problems PS
20. 0 O depending on the impedance of the cable used may not be needed in short networks with few devices but at higher baud rates and as the network length increases their inclusion becomes essential PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 4 Troubleshooting 4 1 Introduction During installation and operation a number of checks should be made to ascertain whether the MCM unit is performing correctly and to determine possible causes if it is not 4 2 Use of the MCM Config utility The MCM Config software is a simple test utility provided by Artesis for examination of waveforms and can connect to a single MCM unit using the RS485 serial line on the rear of the instrument If a network is available MCM Config can be installed on the host computer otherwise a portable laptop machine equipped with a suitable RS232 485 converter should be made available for this purpose 4 MCM Configuration Tool 2 0 Address Select Command 1 v Get Status X Send Connection Status BE Response received TCP IP 192 168 26 254 4001 Timeout 3000 msec MCM Status Motor Status Data Available EJ Busy E In Check O Improve Alarm L1 Monitor Error o Update Warning E No Data OK Watch Line Watch Load Examine 1 Examine 2 oy OO 44 Section 4 Troubleshooting 4 2 1 MCM Config View When connecting to an MCM unit the following steps should be observed Select the pc communications settings by pre
21. 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 3 4 8 2 such as voltage imbalance isolation problem of cabling capacitor motor connector terminal slackness defective contactors etc Mechanical Parameters The parameters in the second group are sensitive to mechanical faults such as load imbalance misalignment coupling and bearing problems They are called Mechanical Parameters 1 12 These parameters are obtained from the frequency spectrum of the electrical signals by extracting information from the line current and voltage supplied to a motor The variances in the stator rotor air gap are reflected back in the motor s current through the air gap flux affecting the counter electromotive force Therefore current carries information related to both mechanical and electrical faults Hence faults will exhibit a change in the frequency spectrum of the current evident in specific frequencies MCM uses the power spectral density psd obtained from the differences between the expected current obtained from the model and the actual current These differences include only abnormalities generated by the motor Therefore they are immune to the noise or harmonics present in the supply voltages The mechanical parameters indicate the power level of the difference between measured and estimated current at frequencies at which they occur in terms of number of standard deviations If they exceed the threshold value which is 8 an abnormalit
22. 5 Running LEARN and IMPROVE iode en tit sate as neto eode duret ele pL LIE RH EeU ONE 27 3 4 6 Running RESUME and UPDAT E cete ren ba recu Hoe dete deste carus di e Rede cudos 30 PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 3 47 Advanced used ente eee ensi de a nde Tada Bos ete eer erue e tee dete ennt 31 3 4 8 Equipment Faults and their diagnoses using MCM c cccccsssssssecesssesssseeeeeeees 34 3 4 9 Interpreting MCM fault indications cccccsssssccceesssssseeceesesesnseeeeesessseseeeeseees 36 4 Troubleshooting reco eoo ae R E e Oa oni tepore EeS oov de E Era PX T DEN UR ndr 44 4 1 IM TROGUCUION ROM E a 44 4 2 Use of the MCM Config utility eese eene 44 4 2 1 MCM Config View riassunse oratna aeae nennen nnn a aa d rsen nnns nasse nein nena 45 4 3 Fault Diagnosis dano esiri enesenn CT 48 4 4 SEVICE earr SEEE ees TOEA TED EA 49 4 5 IS EDI 49 DEED Pe mM 50 5 1 Appendix 1 MCM Error alarm and warning conditions eesssese 50 5 1 1 Eror Coriditioris 5 ottenere ct eben eade pisi 50 5b 1 2 Alarm Conditions eoi eene ne ee od tes reed derer ads 51 5 1 3 Warning Conditions snan ienr e e a aa e a aaae EES 53 5 2 Appendix 2 Current and voltage sensor selection seeeeeeeeene 54 5 2 1 Inverter driven systems ccccssccecesssseceeeesssssseeceesessseeeesssesueeecessssssaeeeeessesaae
23. A N A frequency MHz only Run Learn Number of iterations Edit 4 20000 3000 Settings iterations used in Display 400 LEARN PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 64 Edit Submenu Description Type Range Default Settings items Value Menu Group Improve Number of iterations Edit 1 20000 8000 iterations used in Display 12000 IMPROVE Update Number of iterations Edit 10 1500 iterations used for Display 20000 UPDATE Flash save Number of iterations Edit 1 1000 100 rate after which the flash Display will be automatically updated with new data If the device is operating in a noisy environment this value should be set to a low number to ensure minimal loss of data due to power outages and resets etc Section 5 Appendices Edit Submenu Description Type Range Default Settings items Value Menu Group Locallockout Requires that Edit ON OFF OFF passwords be Display supplied prior to entering all operating modes In IMPROVE UPDATE MONITOR modes only the output relay can be set to close on the rising edge of a transition above the set fault level The relay can be reset by selecting either Acknowledge or Reset relay Acknowledge will cause the relay to close only when the current state is exceeded while Reset will allow the relay to close at the end of the current iteration when if the condition has not bee
24. E Can cause death or serious injury Multiple energy sources present See user manual before servicing Turn off and lock out all power supplying this device before working on this device If the equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired 2 2 1 Safety related symbols on the device Risk of electric shock General warning symbol PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 2 3 MCM Unit Installation NOTE MCM has been designed to mount directly onto the front panel of the motor switchgear cabinet Any other usage is not recommended due to the lethal voltages present at the terminals To mount insert the MCM unit into the prepared 3 62x3 62 inches 92x92 mm cutout on the cabinet panel 0 97 inches 5 mm panel thickness and push until the front of the unit is flush with the panel Insert the side retainers and tighten the thumbscrews on each retainer until the MCM unit is held securely in place e WARNING In common with any device connected to high power electrical supplies only suitably qualified personnel should install and maintain MCM Section 2 MCM Installation 2 4 Current Transformer CT and Voltage Transformer VT Installation 1 WARNING All installation wiring and periodic maintenance of MCM well as its associated circuits invo
25. Line and MCM Inverter 5 1A versions 2 MCM LV and MV Inverter Versions PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 5 8 Appendix 8 Compliance and Certification EMC Europe EMC Directive EN 61326 1 Immunity for 2004 108 EC Industrial Environments EN 61326 1 Emissions for Industrial Environments Australia New Zealand C tick IEC EN 61326 1 Immunity for Industrial Environments IEC EN 61326 1 Emissions for Industrial Environments Electrical Safety Europe Electrical Safety Directive 2006 95 EC EN 61010 1 Safety Requirements for Electrical Equipment Australia New Zealand C tick IEC 61010 1 Safety Requirements for Electrical Equipment North America UL Listed Canada and US UL 61010 1 Safety Requirements for Electrical Equipment C US LISTED MEASURING EQUIPMENT 3SG7 CE 76 N1235Z LE Alo6poso ibHas cepmonkayna
26. N buttons allows the user to select and display the most recent values for the parameters calculated by MCM Advanced use It is possible to customize the behavior of MCM by adjusting various settings As usual a valid password must be supplied before the Edit Settings menu can be entered The following table summarizes the settings that can be changed together with their significance It is recommended that the original values of each setting be recorded PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 52 prior to changing them After changing certain settings it may be necessary to relearn the motor Menu Group Setting Usage Harmonic Harmonic Calc Switch on off calculation of harmonic values Note Values that the calculation of harmonic values can significantly lengthen the cycle time Signal Select The channel number 1 6 of the channel to be used for harmonic calculations Calibration Calibration The calibration constants for the sensors on each channel Alarm Voltage Maximum permitted voltage imbalance Thresholds balance 96 Current Maximum permitted current imbalance balance 96 Voltage range 26 Maximum voltage range as percentage range around nominal Max Current 96 Maximum permitted current upper limit as percentage above nominal Low voltage 96 Minimum acceptable level below which voltage is considered to be zero for line and power fault alarms as
27. NRTL to appropriate UL or CSA product safety standards Only SELV voltage transformers must be used with MCM units Over Voltage Category CAT II Impedance 3 5MOhm Phase to Phase Quantity Nominal Minimum Maximum Maximum Units Notes Measurable permissible See Key Voltage 480 277 20 520 300 606 350 VAC 1 2 Frequency 50 60 45 65 65 Hz 1 50 60 25 90 90 Hz 2 KEY Number MCM Version 1 MCM LV and MV Line and MCM Inverter 5 1A versions 2 MCM LV and MV Inverter Versions 14 Section 5 Appendices CURRENT MEASUREMENT Current transformer and current sensors must meet local standards and regulations For North America current and voltage transformers must be certified by an OSHA appointed NRTL to appropriate UL or CSA product safety standards Max 250VAC CAT II for 5A and 1A units Max 30VAC SELV for MCM Inverter units used with 50 400mA secondary output current sensors Over Voltage CAT II Category Quantity Nominal Minimum Maximum Maximum Units Impedance Notes Measurable permissible Approx See Key Current 5 0 2 7 20 A 15 3 mOhm 1 5A For 5 s 1 0 04 1 4 4 A 50 mOhm 1 1A For 5 s 50 1 5 70 80 mA 50 Ohm 2 For 5 s 50 100A 180 2 200 100 3 140 mA 25 Ohm 300 For 5 s 500A 300 2 200 6 250 mA 12 5 Ohm 1000A For 5 s 600 2 400 12 500 mA 6 25 Ohm 2000A For 5 s KEY Number MCM Version 1 MCM LV and MV
28. TACTOR gt N PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 5 3 3 High current low voltage inverter driven motors with current range of 201 2000A Hall Effect Sensor amp MCM LV Inverter POWER SUPPLY L R R S e 5 L 31S Jg E o L T T INVERTER FUSE X X Isa E Ez E Ea Et MCM Va LL LV LINE x INVERTER lt 5 3 4 Medium high voltage motors with voltage amp current transformers MCM MV Line Compensation network optional qp m 56 Section 5 Appendices 5 3 5 Medium high voltage Aron connected motors MCM MV Line Compensation network optional 5 3 6 SoftStarter EYPASS Cincumime PS 01 KL 01 REV 00 Menu settings and parameters MCM menu is password protected and the default password for the menu is m The default password can be changed from the MCM menu MCM Motor Condition Monitor Users Manual 5 4 Appendix 4 p ysasyymau ysasyimau 2 ysasyymau T ysasyymau dinuibuojba guiM jnujaspajaJMopulM dijmux3bqmopuim M074UJ aur YBIH 44 aur pjousa uj poo1 pjoysasysabuoy
29. TE modes it has insufficient data to indicate the motor status accurately Under such conditions a blank string may be displayed instead of the motor status This is a temporary condition and should last only for the first data cycle As a result of internal error handling the blank string may occasionally be seen Again this is temporary and will pass by the start of the next data cycle Although MCM should have met the majority of working conditions in the learning mode it is still possible for it to fail to recognize a particular working point In such a case the user can elect to add the current operating point to the internal database using the UPDATE feature Running UPDATE will cause the internal database to be updated with the new information over a preset number of cycles Once the count of iterations exceeds the preset number MCM will automatically return to MONITOR without user intervention The number of update cycles can be set from MENU Edit Settings Password Run settings Update iterations If it is necessary to learn the new operating conditions of the motor in order to add them to the existing database UPDATE can be started in two ways Firstly in IDLE mode the Update option should be selected and ENTER pressed Secondly from MONITOR the RIGHT button should be pressed to display the message Press ENTER for UPDATE Then ENTER pressed to select the mode As in the learning mode sequentially pressing the UP or DOW
30. Users Manual Artesis Motor Condition Monitor NO CHANGES ALLOWED TO THIS MANUAL WITHOUT PRIOR APPROVAL FROM APPLICABLE APPROVALS AGENCIES MCM Motor Condition Monitor PS 01 KL 01 REV 00 Section 1 Overview 2010 Artesis All rights reserved The information contained in this document is subject to change without notice Denotes a trademark of Artesis MCM The following are trademarks of the legal entities cited Printed in Turkey Uncontrolled when transmitted electronically Contact Information The following contact information is provided for those times when you cannot contact your local representative Mailing Address Artesis A S Kemal Nehrozoglu Cad GOSB Teknoparki Hightech Binasi Kat 3 B 10 Gebze 41480 Kocaeli Turkey Telephone 490 262 678 8860 Fax 90 262 678 8855 Internet www artesis com PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual Additional Information WARNING Lethal voltages and currents are present at the input terminals of this device Accordingly this MCM unit should be installed and maintained only by qualified competent personnel who have the necessary training and experience appropriate to high voltage and current devices MCM must be used in accordance with all local and national codes for the installation and operation of electrical equipment Observe all site specific procedures including local lockout and tagout
31. a sensor Therefore any fault of the equipment that affects the motor or the three phase system is also observed by MCM MCM first learns the motor based system for a period of time by acquiring and processing the motor data The results of the processed data are stored in its internal database and a reference model is established This reference model basically consists of model parameters their mean values and their standard deviations While monitoring MCM processes the acquired motor data and compares the results to the data stored in its internal database If the results obtained from the acquired data are significantly different from the reference model MCM indicates a fault level The level is determined by taking into account the magnitude and the time duration of the difference In total MCM monitors and compares 22 different parameters model parameters These parameters are classified into three groups electrical parameters mechanical parameters and fit parameters These are explained in detail in the following sections 3 4 8 1 Electrical Parameters There are 8 parameters in the first group that are called electrical parameters These are the network equivalent parameters and are correlated to the physical parameter of the motor like inductances resistances etc They are sensitive to electrical faults developing in the motor MCM evaluates and analyzes the differences between the model parameters at any instant and the average
32. and rerun CHECK PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 5 6 2 Running MCM Learn Check motor and MCM cabling power etc Adjust the Learn Iterations if necessary Select Run from the main menu to start the learning mode Adjust Lode threshold rerun CHECK and then LEARN YES Section 5 Appendices 5 6 3 Running MCM MONITOR IMPROVE UPDATE Rectify alarm conditions Resume started properly MCM is now monitoring the status of the attached motor system LEARN not properly completed Repeat LEARN and rectify any alarm conditions Go to A1 PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 5 6 4 Running MCM Alarm conditions Voltage Current balance The phase voltages currents are not balanced e Adjust balance threshold e Investigate and rectify imbalance Voltage range The voltage on the specified channel is out of range e Adjust thresholds e Investigate input voltage levels High Current The current on the specified channel is out of range e Adjust threshold e Investigate reasons for out of range currents Motor not running MCM measures one or more current phases to be less than the no current threshold indicating that the attached motor is not running e Check that motor is running e Check that the Low Current threshold is suitable e Check current connections to motor sensors and MCM Motor connection fault One or two of the measur
33. are scaled You can turn off any of the waveforms you do not wish to see by disabling the appropriate checkbox next to the label indicating this waveform Voltage and Current Waveforms O O L1 m E m iv Vr Iv Vs lv Vt Iv Ir Iv Is Iv It PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 4 3 48 Fault Diagnosis A number of common problems can be diagnosed by inspection of the measured waveforms and it is good practice to check the waveforms of each unit as part of the commissioning process With the motor running and power applied to MCM Voltage phases should have the correct RST phase relationships separated by 1209 The current phases should be in the same order as the voltage phases and also separated by 1209 Any phase ordering missing or duplicate phase problems should immediately be seen from the waveform display For star connected motors it is essential that the phase angles between corresponding voltages and currents lie between 0 and 909 Motors connected using the delta topology have an extra 309 phase shift and the current phase angles should lie between 30 and 602 In either case check that the motor topology has correctly been entered on the MCM front panel and that the currents do indeed correspond to the correct voltages It is important to perform this test with the motor under loaded conditions as loading can significantly affect the measured phase angle For delta connections check
34. assword be changed in order to prevent unauthorized access to the device The Edit settings menu At this level the following Edit Settings menu items are accessible Motor values Alarm thresholds Harmonic values Versions Comm settings Run settings Motor settings Phase Ordering Calibrati h Change password PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual Editing and displaying menu items Please refer to the appendix for a table of these menus and their sub menu items To edit a particular item first select the item to edit and press and confirm ENTER As before use the UP and DOWN buttons to scroll vertically through individual digits and the LEFT and RIGHT buttons to change the digit being edited Some variables can only take discrete values represented by character strings and in this case vertical scrolling will shift through the allowed values For example the Parity value under the Communications settings menu can only have the values EVEN or ODD and scrolling will repeatedly cycle through these values Menu Paths Throughout this manual paths to menu items are represented by the word MENU followed by the list of sub menus required to reach the item separated by a forward slash For example the path of the Parity value given in the preceding paragraph would be given as MENU Edit Settings Password Comm Settings Parity The forward slash can be thought to represent the action of pressing and confi
35. d in order to start or quit a Check Motor or Monitor mode Its purpose is to prevent any unauthorized tampering with MCM Remote commands over the serial line are unaffected Relay thresholds Set the fault level for activating the output relay in MONITOR mode If set the relay is triggered by a change from a lower to a higher fault level any time the level is equal to or above the set level Current stability 96 When obtaining data MCM requires relatively unchanging current signals If the variation in the amplitude of the current exceeds this threshold MCM will reject the data The alarm UNSTABLE LINE is often seen when the current stability is set too low 3 4 7 1 Monitoring motor and line parameters In all operating modes and after CHECK MOTOR has finished it is possible for MCM to display selected parameters Sequentially pressing the UP or DOWN buttons allows the user to select to display the most recent values for the parameters in the following table PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual Displayed Parameter Unit Admittance A V Phase angle E Power factor Active power W Voltage balance Current balance V4 RMS V V RMS V V3 RMS V l RMS A l2 RMS A l3 RMS A Line frequency Hz Fit Parameter 1 Fit Parameter 2 Total Harmonic Distortion THD 3 13 Odd harmonic levels 96 3 4 8 Eq
36. digit using the LEFT or RIGHT buttons and again scrolling with the UP and DOWN buttons A schematic diagram showing the menu hierarchy is shown in the appendix at the end of this manual Configuring for use Master reset When first installed the MCM unit will be configured for the default factory settings which will need to be changed prior to use At later times the factory settings can 3 3 2 3 3 3 Section 3 MCM Use be restored by pressing and holding down the LEFT button for about 4 seconds during power up of the device until the string Press ENTER for general reset appears At this stage pressing ENTER will initiate the reset Pressing any other button will cause the reset to be ignored and the device will continue Entering the password To configure the unit select the Edit Settings mode and press and confirm ENTER In order to proceed further it will be necessary to enter a password NOTE 4 The factory setting for this password is the string m and can be entered using the UP and DOWN buttons to cycle through the alphanumeric characters a through z 0 through 9 The LEFT and RIGHT buttons are used to shift the active character in the string To input the password m repeatedly press the UP button until the letter m appears in the first position Press and confirm ENTER and then press ENTER again to enter the Edit Settings menu It is recommended that at a later time the p
37. e Gauge Minimum 30 AWG Maximum 12 AWG Current Connector Screw Torque Minimum 0 5Nm 4 4 Ib in Maximum 0 6Nm 5 3 lb in Voltage Connector Wire Gauge Minimum 30 AWG Maximum 12 AWG Voltage Connector Screw Torque Minimum 0 5Nm 4 4 Ib in Maximum 0 6Nm 5 3 lb in Power Supply Connector Wire Gauge Minimum 30 AWG Maximum 12 AWG Power Supply Connector Screw Torque Minimum 0 5Nm 4 4 Ib in Maximum 0 6Nm 5 3 Ib in Cables of Rear Connectors Cables must be suitable for minimum 80 C 176 F AMBIENT CONDITIONS Operating Temperature 0 40 C 32 104 F Humidity 90 non condensing Pollution Degree 2 Altitude 2000 m 6562 ft IP Rating Front PS 01 KL 01 REV 00 40 whole unit IP20 MCM Motor Condition Monitor Users Manual INPUT SUPPLY VOLTAGE The power supply voltage must be connected to the MCM unit Via a UL listed fuse 15A Over voltage category CAT II 100 240VAC 15 10 47 64Hz 19VA 200mA Use UL listed 15A fuse with proper dh m voltage ratings Voltage 120 300VDC 19VA 200mA Use UL listed 15A c fuse with proper voltage ratings VOLTAGE MEASUREMENT Voltage transformers must meet local standards and regulations For North America current and voltage transformers must be certified by an OSHA appointed
38. e power of the motor to be monitored by the MCM device The three current sensors are connected in series with each of the three the motor power cables Power to the current sensors is provided by separate power sources fitted inside the motor control panel Hall effect current sensors must be used with MCM Inverter units The secondary of the current sensor must be SELV Safety Extra Low Voltage Voltage transformers should be 196 accurate or better with 100V 110V or 120V secondary voltage Line driven systems Current transformers should be 196 accurate or better The secondary current should be either 5A for 5A MCM units or should be 1A for 1A MCM units The secondary of the current transformer has to be SELV Voltage transformers should be 196 accurate or better with 100V 110V or 120V secondary voltage Section 5 Appendices 5 3 Appendix 3 Connection Diagrams 5 3 1 Low voltage line driven motors with current transformers MCM LV Line Li Lz Ls CONTACTOR FUSE X X D Ds Tea Tea De du Vi MCM Ne 1 u LV LINE t 2z Vs SP PE 5 3 2 Low current 5 200A low voltage inverter driven motors Hall Effect Sensor amp MCM LV Inverter v N N 115v E L g USE GND E PE E Lay is bL T E i INVERTER aa iis JCURRENT SENSOR CARD CON
39. ed current phases are missing e Check current connections to the motor the current sensors and MCM Line fault One or more of the applied voltage phases is missing e Check voltage connections to both the motor and MCM e Check that the Low Voltage threshold is suitable Power fault All the applied voltage phases are zero e Check voltage connections to both the motor and MCM e Check that the Low Voltage threshold is suitable Go to D 10 Section 5 Appendices Unstable line The measured voltage and or current signals show too much amplitude or frequency variation for MCM to assess the motor status e This condition is usually only transitory Wait until stability returns e Check that the motor is operating normally e ifthe motor has a soft starter check that it is being bypassed correctly during normal use e Increase Current Instability parameter e if the condition persists contact Artesis AS General fault MCM cannot process the data for some reason This is usually caused by non sinusoidal signals or signals not crossing through zero e Check input voltage and current signals using MCM Config e Ifthe condition persists contact Artesis AS Phase fault The phase angle between two voltage phases is not 120 e Check input voltages to both the motor and MCM Phase angle The measured phase angle between corresponding voltage and current channels was not in the expected range 0 lt q lt 90 e Check input cur
40. een or red boxes inside the MCM Mode MCM Status and Motor Status boxes You can send commands to the MCM by clicking on the Select Command box which brings up a list of available commands Choose commands from the list below to test various functions of the MCM Command Explanation Get Status Updates the status information Go Idle Sends MCM to the IDLE state Check Sends MCM to the CHECK state Update Sends MCM to the UPDATE state Resume Sends MCM to the RESUME state Run Sends MCM to the MONITOR state Get Alarm Gets alarm information from the device Get Error Gets error information from the device Get Warning Gets warning information from the device Get Version Gets MCM s version Take Data Starts acquisition of VI data for later viewing This also enables upload status elements Get RMS Gets RMS values from the device Get Settings Gets MCM settings and displays all the setting values for checking amp editing Download PSD Gets PSD values from the device data Download VI Downloads previously recorded VI data for viewing Use of Take data Data is recommended for latest VI values Check system response by sending a Get Status message This is done by selecting Get Status from the Command selection combo box and pressing the Send Command button If Response Received message does not appear in the Connection Status box in the amount of time specified earlier as the timeout
41. ent limits 0x1000 Motor connection One or more currents were measured below their fault acceptable limits 0x2000 Line fault One or two voltage phases were compatible with zero below No voltage limit 0x4000 Power fault All the voltage phases were compatible with zero below No voltage limit 0x8000 Unstable line The power lines were not sufficiently stable to allow the algorithm to obtain data amplitude and frequency variations of current and voltage were excessive 0x10000 General fault General fault consisting of one or more of No data obtained no zero crossings detected perfect phase balance voltage or current 0x20000 Phase ordering The phase ordering used by MCM is incorrect and must be rectified 0x40000 Phase fault Voltage phase angles incompatible with 1209 were detected 0x80000 Phase angle The measured phase angle between corresponding voltage and current channels was not in the range 0 lt 9 lt 7 2 0x100000 Current phase fault The ordering of the current phases was different PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 52 Alarm Number Alarm type Description to that of the voltage phases or the angle between two phases was not 1209 0x200000 Data acquisition fault Division by zero was attempted during data acquisition 0x400000 Range error An illegal value was detected for one or more of the following quantities during data acquisition Calibrat
42. ermore the monitoring software package allows examination of the various parameters MCM uses to determine the status of a motor and to trend the parameters as a visual indication of degradation over time Despite its simplicity and ease of use like any intelligent electronic software based device it is important that MCM is installed and used correctly We strongly recommend that you take the time to study the information contained within the accompanying manuals and to familiarize yourself with the operating principles and practices Use of this manual This manual explains the basic concepts needed to install and use MCM The appendix at the end of the manual provides information that may be useful to the general user For further specific details please contact Artesis PS 01 KL 01 REV 00 Section 2 MCM Installation 2 MCM Installation 2 1 Preliminary checks Please inspect the contents of the MCM package and ensure that they agree with the information in the packing list In the event of any missing or damaged items please contact your supplier immediately Check also that the power range of the MCM unit is suitable for the motor to be monitored The device type can be found on the MCM label Artesis will not accept responsibility for damage caused to or by any MCM unit that has been incorrectly installed or installed on a motor system outside the indicated power range 2 2 Safety Notes WARNING HAZARDOUS VOLTAG
43. es on V3 and V2 respectively are reversed The order of the current inputs is also incorrect with IS connected to Iq 142 Ir connected to I 122 and I connected to l3 132 Furthermore the polarities of the two currents ls and Iz have been reversed I3 has been exchanged with l12 and l3 with 132 NOTE Once MCM has determined the correct phases the user should not change the input connections without running CHECK MOTOR again The algorithm used by MCM to determine the phase order yields two solutions depending on the motor loading and extra information is required to obtain the correct sequence To this end MCM compares the measured RMS values for the currents with the nominal current entered by the user If the ratio of the measured current to the nominal current is greater than the value of the Load threshold expressed as a percentage the motor is assumed to be working under loaded conditions and the appropriate solution is chosen Otherwise the motor is assumed Section 3 MCM Use not to be loaded It is thus important to enter an accurate value for the nominal current Even so it is still possible for MCM to choose the wrong solution which will yield unrealistic values for the phase angle when the loading on the motor changes in use MCM provides the possibility of overriding the detected phase sequence from the menu item Order Override under MENU Edit Settings Phase Ordering Order Override Cha
44. for further details Low voltage inverter driven systems The current sensors employed by MCM for inverter driven systems are Hall effect type requiring an external DC power supply The motor current rating should be checked carefully to ensure compatibility with the sensors provided Please refer to the appendix at the end of this manual for further details on sensor selection High current sensors for currents greater than 200 A need to be mounted separately at a convenient location within the switchgear cabinet together with their external power supplies Smaller sensors are mounted on the same circuit board as the power supply and should be placed together at the chosen location In both cases the cable carrying power to a single phase of the motor must be passed through the central hole in the appropriate current sensor and secured The power supply ground should be connected directly to the l12 122 and I32 pairs of current measurement terminals on the rear of the MCM unit Voltage connections Ve Vs Vr should be made directly to their respective voltage measurement terminals V4 V2 V3 at the rear of the unit NOTE MCM is not recommended for use with inverters operating at a chopping frequency lower than 2 kHz Please refer to the connection diagrams in the appendix at the end of this manual for further details PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 2 4 5 Medium High voltage systems
45. greater than 1 5 a manner bearing no exceed the third frequency threshold and the frequencies of both line and load changes are below their corresponding thresholds relation to the learned reference model due to a developing fault in the motor and or in the systems connected to the motor The Load line status parameter of MCM takes values between 0 and 15 Its possible values correspond to combinations of the bits of a binary number with each bit having the significance given in the following table Section 3 MCM Use Bit Value Condition 0 1 Voltage values are outside the range encountered during the learning phase 1 2 The vector sum of the three phase voltages voltage balance is out of the range encountered during the learning phase 2 4 Fluctuations in the three phase voltages have changed in comparison with the fluctuations encountered previously over a moving window 3 8 Loading conditions are different from the loading conditions encountered during the learning phase Thus a Load line status value of 9 would result from the arithmetic sum of 8 and 1 and would correspond to conditions 0 and 3 holding and conditions 1 and 2 being false This would mean that both the voltage values and the loading conditions differ from the conditions met during the learning period but that the voltage balance and voltage fluctuations were consistent The motor status values displayed
46. h simple and straightforward once the basic concepts and principles are understood This section of the manual is designed to introduce these concepts and to demonstrate how MCM is set up how to check all the connections and settings how MCM learns the characteristics of the system it will monitor and finally how to actually monitor the motor system It is recommended that first time users read this section carefully as successful operation requires that MCM is set up and used correctly Flowcharts for the main operations are provided in the appendix at the end of this manual to help users navigate their way through the various steps involved with setting and running MCM for the first time 3 2 The front panel OK Watch Line Watch Load Examine 1 Examine 2 Clear Enter Selection Buttons Power Indicator 3 2 1 Confirming ENTER and CLEAR Once the sensors have been connected and power has been applied to the MCM unit the Power indicator light and the Liquid Crystal Display LCD on the front panel should both be lit The LCD should display the message IDLE on the top line indicating that the unit is idle and waiting input from the user When being used for PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 3 2 2 3 2 5 3 3 3 3 1 18 the first time the message Bad flash data Press Clear may be displayed The user should repeatedly press the CLEAR button until the message disappears Once data has been w
47. hase a larger number of learning iterations is not generally required The number of learning iterations can be set from the menu path MENU Edit Settings Password Run settings Learn iterations PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 3 4 5 2 3 4 5 3 28 IMPROVE Selecting RUN from the main menu will initiate a new LEARN period If data from a previous leaning period exist the following message will be displayed Lose learn Data Clear to exit The user should press the CLEAR button if it is not desired to overwrite the existing data and ENTER if it is Once the initial learning period is complete the MCM unit will automatically try to improve its estimation of the motor characteristics by updating the database obtained during the learning mode The database is updated with different load and line conditions in the Improve mode The duration of the Improve mode is determined by the number of Improve iterations set from the menu path MENU Edit Settings Password Run settings Improve Iterations It is recommended that this value be set to between 8000 10000 iterations An important difference between this mode and the initial learning period is that MCM monitors the motor status during IMPROVE but does not during LEARN Once the IMPROVE stage is complete the MONITOR phase will automatically continue without user intervention This is the main operating mode and MCM is expected to spend mo
48. hase ordering Phase ordering is different from the values set 0x10 Unstable system Instability was detected for the system PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 5 2 5 2 1 5 2 2 54 Appendix 2 Current and voltage sensor selection Voltage transformers current transformer and current sensors must meet local standards and regulations For North America current and voltage transformers must be certified by an OSHA appointed NRTL to appropriate UL or CSA product safety standards When selecting a current sensor both the maximum current the motor will handle in practice and the type of motor drive used should be considered Systems employing an inverter will generally limit initial inrush to a maximum of about 15096 of nominal current With a soft starter system this limit will probably be 40096 Sensors must be able to withstand the maximum expected inrush currents and should be selected accordingly Sensors should be selected such that the nominal motor values for current and voltage are around 7096 of the corresponding sensor rating Alternatively for current transformers the secondary current at nominal motor current should be between 3 5 4 5A and the same for voltage transformers Failure to do so will result in a loss of sensitivity and the ability of MCM to detect motor degradation or change Inverter driven systems Sensors used for measuring currents should be selected depending on th
49. he behavior of the motor is slightly different than the reference model At least one of the medians over one and a half times the window of the maxima of the three groups of parameters is above the second threshold There is a considerable difference in behavior between the reference model and the motor At least one of the medians over two times the window of the maxima of the three groups of parameters is above the third threshold and the median over the window or one and a half times the window of the maximum of another group of parameters exceeds the first or the second threshold There is a significant difference in behavior between the reference model and the motor At least one of the medians over two and a half times the window of the maxima of the three group of parameters is above the fourth threshold and the median over the window or one and a half times the window or two times the window of the maxima of the group of parameters exceeds the first or the second or the third threshold The motor is behaving in a manner totally different from the reference model Motor Status 2 also takes values between 1 and 5 The calculation of Motor Status 2 is based on counting the frequency of the values of Motor Status 1 that are greater than one and the frequencies of any load and line changes over larger windows Window sizes and frequency thresholds used for the calculation of Motor Status 2
50. heck on all motor connections to determine the phase ordering and that a motor is connected and running It also checks among other things that the voltage and current levels are within set limits and that the phase angle between the V4 and h1 132 channels is appropriate If MCM detects that some condition is not met an alarm is raised which the user should investigate and remedy before proceeding further 3 4 3 1 Check mode command The CHECK MOTOR mode is entered using the menu item MENU Check Motor Password NOTE If the Local Lockout setting is ON it is necessary to supply a password before access to the CHECK MOTOR mode is granted The password is the same as used to access the Edit Settings menu Once CHECK MOTOR has finished it will display either the message Motor values or a warning or alarm indication At this point the UP and DOWN buttons can be used to cycle through a list of calculated physical parameters If an alarm is present pressing LEFT or RIGHT buttons will cycle through the list of alarms Many of the alarm conditions relate to the calculated physical values and it is often useful to check the calculated values of the relevant parameters when trying to understand the origin of an alarm condition Pressing CLEAR will return to the IDLE state The software utility MCM Configuration Toll found on the companion CD can be helpful when diagnosing problems during initial Edit Settings The program shou
51. iation or agency that is in control of product shall dispose of it in a manner that is in violation of any applicable federal state local or international law Artesis is not responsible for the disposal of the product at the end of its life or at the end of its use 1 3 Section 1 Overview Contents OVEN VIC WY occ ceri arp sdb eie eue E IEEE E 5 1 1 INtrodUCt ON sieisen e EN E a aaae ene aE E Eaa Aan E EEE 5 1 2 Use of this manual i eee re oie sat ea dele nre en oai ARa aE To aaan i 5 MCM Installation cs asec ces Paden eanne tessons u asia cUep da seia aaan EE EN aai 7 2 1 Preliminary checks irri ete en e ete iri tete To ete cec opea sin re Pe TER RT de 7 2 2 Salety NOtes in HRIRDO HEN ie de ee 7 2 2 1 Safety related symbols on the device seesssseee eene 7 2 3 MCM Unit Installatigri c iii isi orent eerte of eed ertet erga ee eo eoo er Pe ae Ce Dvd 8 2 4 Current Transformer CT and Voltage Transformer VT Installation 9 2 4 1 Low voltage line driven systems sessi 11 2 4 2 Low voltage inverter driven systems eesesseeee eene ennemis 11 2 4 8 Medium High voltage systems esses enne enne nnne nnne 12 2 5 Rear panel connections cccccccesesssecececsssnsnseeeescsssseeececsesssseeeeeseessaeseesesesesseeeeesees 12 2 5 1 Protection against pickup of electromagnet interference on the power lines 13 2 6 Applying power to the MOM Unii
52. ion constants balance values admittance estimated physical parameters 0x800000 Frequency range CHECK MOTOR and LEARN only The measured frequency differed from the nominal value During the learning period MCM learns the motor only at the dominant frequency In inverter driven systems it is important to set the nominal frequency to this dominant frequency otherwise MCM may never complete the learning period This condition is relaxed during normal monitoring IMPROVE and UPDATE where unlearned frequencies are updated automatically 0x1000000 Frequency tolerance Illegal value for the mean frequency IMPROVE UPDATE and MONITOR 0x2000000 Noisy data The estimated admittance is inconsistent with the measured RMS values for voltage and current This usually indicates excessive noise in the data 5 1 3 Warning Conditions Section 5 Appendices Warning Warning Type Description Number 0x01 Test frequency MONITOR IMPROVE UPDATE only The range measured frequency was different than i e outside the threshold of the LEARN frequency 0x02 Residual error An unexpectedly large value was calculated for the modeling error This is generally an indication of an unstable line condition and will usually pass 0x04 Data size reset Values for some quantities were checked and found to be outside their allowable limits The values were reset to the upper or lower limits 0x08 P
53. it and it should be returned to Artesis If any phase has a marked difference in amplitude to other similar phases the calibration constant for that phase should be checked If no external sensor is attached i e for low voltage motors the calibration constant should be 1 If the calibration is correct the sensor may be defective and should be changed Check the current balance levels using the MCM front panel A value below 1596 is acceptable but above 1596 the Total Harmonic Distortion THD on all current phases should be checked Normal levels for THD can be up to 6 depending on conditions For values higher than this level check whether the distortion originates from the motor or the line by measuring the THD present at other motors connected to the same supply If the same level for THD is measured at other motors the line supply is suspect and should be investigated as high levels can damage motors in the long term Otherwise the motor is probably already damaged in some way and should be investigated Check the voltage imbalance levels using the front panel A value below 596 is deemed satisfactory Above this level check the THD levels on each voltage phase Levels above 596 should be investigated The ability of MCM to detect faults will be reduced as voltage imbalance increases Check that all waveforms disappear when power is removed from the motor Servicing MCM contains no user serviceable parts and must be returned
54. ivate again only when PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual the motor status exceeds the current value Reset relay will allow the relay to activate again when the same preset conditions are next met possibly as soon as the next data cycle Relay output absolute maximum ratings Current A Voltage V 2 0 30 DC Relay Output States Relay Contacts State NO COM NC COM Relay active Closed Open Relay inactive Open Closed 3 4 9 6 X Connecting to the serial port MCM can be connected to a PLC or other monitoring system such as MCMScada via the RS485 port on the rear of the device Artesis makes available its proprietary protocol on request in document entitled MCM System Communications Protocol Document for End Users Please contact Artesis to obtain this document RS 422 port connections Pin Description Notes 1 Receive A Rx For 2 wire connect to Tx 2 Receive B Rx For 2 wire connect to Tx 3 Transmit A Tx 4 Transmit B Tx 5 Common 0 Optional connection to local ground via 100 Q resistor 42 Section 3 MCM Use Connecting devices to a RS422 4 wire network ARTESIS MCM COMMUNICATION CONNECTION DIAGRAM 1 ARTESIS MCM 2 ARTESIS MCM 3 ARTESIS MCM 4 ARTESIS MCM CONVERTER Converter ARTESIS MCM Cable Wirin Tx 9 9 Rx Tx Rx Fox lt Tx
55. ld be installed on a portable PC and the PC connected via a RS232 RS485 converter PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 3 4 4 26 to the communications port on the rear of the MCM device Using the software it is possible to upload and display the voltage and current waveforms measured by MCM Inspection of these waveforms can reveal problems caused by missing phases phase ordering phase imbalance etc Please refer to the MCMScada documentation and to the trouble shooting section of this manual for further details Setting and checking the input connections When the CHECK MOTOR menu option is selected MCM first determines the relative order of the voltage phases using the V4 channel as an arbitrary reference It then attempts to place the current channel pairs in the correct order and polarity The order determined by MCM can be displayed by entering the EDIT SETTINGS menu and selecting MENU Edit Settings Phase Ordering Phase Order On this menu the voltages are denoted by the letters R S T and currents by r s t A sign preceding each letter indicates that the corresponding signal has an extra 180 of phase shift i e that the polarity of the signal is reversed Similarly a sign preceding a letter indicates that the polarity is correct For example R st T r S t The above phase ordering display would indicate that relative to the first voltage R phase on input V4 the S and T phas
56. lves high voltages and currents While this manual suggests several safety and reliability steps it must be used in conjunction with the safety codes in force at your location Failure to practice safe working procedures is likely to cause damage to the installation severe injury and or death All work including handling of electrical circuits during Installation wiring and periodic maintenance must be done only by qualified personnel Neither Artesis nor its agents may be held responsible for damage or death arising out of the wiring and or VT CT or other external circuits Current and voltage transformers must meet local standards and regulations For North America current and voltage transformers must be certified by an OSHA appointed NRTL to appropriate UL or CSA product safety standards PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 10 WARNING CURRENT TRANSFORMERS Incoming power must be de energized before installation Before wiring de energize the CT secondary by shorting it via a shorting block The current transformer must have its secondary terminals short circuited or connected to MCM unit before energizing the primary circuit Under no circumstances must the CT secondary be left open circuited even momentarily when primary current is flowing This causes high voltages that will overheat and explode the secondary of the CT and damage the instruments as well Bef
57. mum acceptable Edit 0 100 15 level below which Display 20 voltage is considered to be zero for line and power fault alarms as 96 of nominal Low current Minimum acceptable Edit 0 100 96 15 level below which Display 20 current is considered to be zero for motor not running alarm as of nominal Current Threshold for current Edit 0 100 15 Instability variation during data Display 45 62 Section 5 Appendices Edit Submenu Description Type Range Default Settings items Value Menu Group Load Used by the phase Edit 0 100 96 30 threshold ordering algorithm to Display set the loading threshold If the ratio of actual current to nominal current is more than the value of the Load threshold in 96 then the motor is considered to be working under load and the appropriate phase ordering selected Otherwise the motor is assumed to be unloaded Versions Firmware Release version of Display N A N A version unit only Database Database version for Display N A N A version remote monitoring only Algorithm Algorithm version Display N A N A only Hardware Hardware version Display N A N A version information only Type Line or Inverter Display N A N A versions only Flash Flash type Display N A N A only Powerrange Whetherthe unit Display N A N A works with low only 700V Or medium high voltage motors Crystal freq System clock Display N
58. n cleared Relay Edit OFF OFF threshold Display WLoad Examine1 Examine2 PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 66 Edit Submenu Description Type Range Default Settings items Value Menu Group Phase Phase Override the phase Edit ON OFF OFF Ordering override ordering determined Display automatically MCM during CHECK MOTOR If set the order can be changed manually from the following item Phase order The current phase Edit ordering Voltages Display are RST currents rst Preceding or indicates inversion 1802 phase shift Use UP DOWN to edit phase at cursor Change Set a new password N A N A password Default values for inverter models All the other models use default values given in the table above Section 5 Appendices 5 6 Appendix 6 Flowcharts for MCM use 5 6 1 Running MCM Edit Settings and Check Motor Run motor system and switch on power to MCM Enter EDIT SETTINGS and provide at least the following settings Calibration constants e Motor settings nominal voltage current frequency and speed motor connection type Required number of iterations for LEARN mode Communication settings if using a network Ensure that Local lockout is OFF Return to the main menu and select CHECK MOTOR Correct alarm conditions please refer to accompanying alarm flowchart Adjust Load threshold
59. nging the value of this item from OFF to ON allows the detected phase ordering to be altered by moving the cursor to the required position and scrolling UP DOWN to select the desired value It is also possible to fine tune the algorithm by altering the value of the load threshold A higher value will tend to favor the unloaded solutions and vice versa The load threshold can be found under MENU Edit Settings Alarm Thresholds Load threshold 3 4 5 Running LEARN and IMPROVE 3 4 5 1 LEARN MCM should learn the motor under normal operating conditions The LEARN period consists of a preset number of data acquisition cycles and periods of data analysis Once the preset number of cycles has been reached the acquired and preprocessed data are further processed to produce a database consisting of a collection of data sets representing the behavior of the motor system under the load conditions that the motor has met in practice It is therefore important to have the motor operating under its expected running conditions during a learning period In order to adequately cover the range of load conditions experienced by a motor system a sufficient number of acquisition cycles or iterations is required NOTE We recommend that you use somewhere between 3000 to 4000 iterations as 4000 iterations typically provide adequate coverage under most load conditions Since additional learning can also be performed if needed during the testing p
60. nning MCM Alarm conditions esses ennemi 70 5 7 Appendix 7 Technical Specifications eene 73 5 8 Appendix 8 Compliance and Certification cccccssssssccecessssseceeesssessnseeseessssenees 76 Section 1 Overview 1 1 1 2 1 Overview Introduction MCM is a revolutionary tool in the battle to keep electric motors and machinery running at peak performance whilst maintaining high plant productivity levels Used correctly this unique instrument is capable of monitoring three phase AC motors of all sizes and power levels to provide clear unambiguous indications when the performance of a particular motor or even the machinery it is connected to begins to degrade The numerous transducers employed by other less advanced instruments have been replaced by three current sensors and three voltage sensors familiar to all those involved with the measurement of electrical quantities making the system straightforward to install and use without in depth training of personnel In addition to its unique capabilities as an intelligent condition monitoring device MCM can also perform many of the functions of and indeed replace the more traditional energy monitoring and data logging instruments For applications involving the monitoring of many motors and associated machinery the networking options available with MCM allow units to be connected together to a host terminal where they can all be viewed together Furth
61. ny other device on the same node PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 3 4 3 4 1 3 4 2 3 4 2 1 22 It is recommended that the motor serial number or any other short identifier string be entered as a means of identifying the motor to the software This is not obligatory and both the networking software and MCM can function without this information Other communications settings All other communications settings should be left at the factory defaults if the MCM networking software is being used If another software package is employed i e SCADA software please refer to its documentation for communication settings MCM can use both RS422 4 wire and RS485 2 wire standards The RS422 standard can be used for up to 19200 Baud rates and the RS485 standard can be used for up to 9600 Baud rates The recommended communication standard for MCM is RS422 4 wire Running MCM Introduction Having configured MCM for a particular motor it can now be used for its intended purpose of monitoring and assessing the condition of the motor In general this involves first running MCM to measure and learn the properties of the motor and then running MCM in its test mode to perform the actual monitoring NOTE Without the learning period MCM has insufficient information on which to base its decisions as the motor ages and will not perform to its specifications For this reason MCM ensure
62. ore disconnecting any MCM unit to or from a current transformer the secondary terminals of the transformer should be shorted using a link capable of carrying several times the nominal output current i e at least 10A WARNING VOLTAGE TRANSFORMERS Incoming power must be de energized before installation Never short circuit the secondary terminal of a voltage transformer even this is not in use A secondary short circuit will cause the unit overheat and fail in a very short period of time Before wiring de energize the VT secondary by opening the circuit or removing the fuse Do not short the VT secondary Before performing any work on a voltage transformer its fuse must be removed or switch opened Use a 1 Amp fuse on each voltage input Section 2 MCM Installation 2 4 1 2 4 2 Low voltage line driven systems Three standard 5A secondary current transformers of appropriate ratings are recommended for current sensing please refer to the appendix at the end of this manual for full specifications The secondary terminals of each transformer should be connected to the corresponding current measurement terminal pairs 131 132 121 122 131 132 on the rear of the MCM unit Voltage line connections Vr Vs Vr should be made directly to their respective voltage measurement terminals Vi V2 V3 at the rear of the unit Please refer to the connection diagrams in the appendix at the end of this manual
63. proysasys QA UDaW JN XDW 448 soy Aojdsiq buyduisqns awn SS UIW 82UDJ2 0 DIS2 Z plousaAu WIS Z pjousaJj1d a215 Ja 5n Jag I pjousaJu1 3018 82UDUDA jJnojag iibuaj mopuiM T PIOySaJYLd 32u0J8J0 ba4JN 32UDJ3J0 UIDS 32U0J3J0 1204d Ayyigoysur bag 4 sBupas jy A sbunjes yp3 pjoysasyy fbjay 1n0207 0201 3 DJ BADS S0 4 uonpJaj eyopdn dapso asoug uonoJe1 anouduy apusan 1 p10 uonpJa r W087 puomssog abuny Buuapuo asoyd sumas uny sypdn bay 015 45 abuos samog piousaJt poo1 ypiqp3sui qua14n5 1uaJJn2 M01 sboyo mol JUUNI XOpi abuns 300A a2unjoq uang sup oq 3600A UOISJ A 9JDpJOH UOISJ8A BSDG0 0G UOISJ9 3J0MUJJIJ SpjousaAu uuo v jauuoua Z jouuDu T jauuoys JQUUDY gt A 2 jeuuDu A T jauupuo A uohbJqi5 ung S 195a OU DLJ8S 403044 ad uon euuo bjap asuodsay Kauanbaj puruoN 1u94Jn2 DUI UON aDpyo DuuoN SsoJppoa2Mag sBunyas 103044 sbuas uiuo 3030W 42845 3 D5 HUOWJOH 329jes joubls aiuQuuDH ET 3IUOUUDH TT 3iuOULIDH 6 3IUOUJDH Z 3IUOUJDH S 2IUOUJDH 3iu0UuJ0H T QHL SanjbA 3iuouubH Kauanbaj aur 31u841n SWY zZ waung Sis TUNI SWY aBDYOA SI Z 900A SWY T 2603 0 Swi 32uppq yuan e2up bq 35040A Jamod annoy 10320 JaOd ajGup asoug e2uppnupy sanjeA J0 0JN apl 58 5 5 Appendix 5 Edit Settings Menu items Section 5 Appendices
64. rents and voltages to both the motor and MCM Current phase fault The ordering of the current phases does not correspond to that of the voltage phases or the angle between the current phases is not 120 e Check input currents and voltages to both the motor and MCM Data Acquisition fault A division by zero was attempted in the algorithm This condition is generally caused by a previous alarm indication e Check input currents and voltages to both the motor and MCM e Ifthe condition persists contact Artesis AS Range fault MCM detected an illegal value for an input setting or calculated parameter This condition is often the result of other alarms e Check calibration constants e Check balance admittance and estimated physical parameters values Frequency fault CHECK MOTOR and LEARN modes only The measured frequency was outside the range centered on the nominal frequency e Check nominal frequency setting Frequency tolerance Illegal value for the mean frequency IMPROVE UPDATE and MONITOR PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual Section 5 Appendices 5 7 Appendix 7 Technical Specifications GENERAL INFORMATION Net Weight 1170g Inverter models 980g 2 58lb Inverter models 2 16lb Device Dimensions W x H x L 90x90x140 mm 3 54x3 54x5 67 in Mounting Front Panel Mounting indoor use Relay Contact Rating 30VDC 2A SELV Current Connector Wir
65. ritten to flash this message should not occur again Using the front panel buttons O POWER P Wem Commands are input by pressing one of the six selection buttons on the front of the unit UP DOWN LEFT RIGHT ENTER and CLEAR For instance the user can cycle through the various modes IDLE to CHECK MOTOR to RUN to RESUME and finally back to IDLE by repeatedly pressing the UP button A particular mode can be selected by pressing ENTER when the desired mode is displayed on the LCD The menus are set up on a hierarchical basis with each level representing commands of the same precedence which the user can cycle through by pressing the UP or DOWN buttons Pressing CLEAR has the effect of stopping a particular action and rising up a level in the hierarchy Only Edit Settings has nested hierarchy levels more than two deep In general whenever ENTER or CLEAR is pressed it will be necessary to confirm the action with a second press of the button pressing the other button i e CLEAR after ENTER and vice versa will cancel the action Setting numeric values Similarly numeric values can be entered using the arrow buttons When a value is to be changed use the LEFT or RIGHT buttons to move the LCD flashing cursor to the first digit to be edited and repeatedly press either the UP or DOWN buttons to scroll through the available alphanumeric characters until the desired one is displayed Subsequent digits can be edited by moving to the next
66. rm conditions may occur during any monitoring phase If CHECK MOTOR has previously been run on the motor it is likely that the alarms represent transient conditions present on the power lines However it is suggested that any alarm representing a condition that could affect the performance of the motor should be recorded and investigated as a potential cause of motor degradation As in CHECK MOTOR if an alarm is indicated the most recent physical values available for the motor can be displayed using the UP and DOWN buttons Examination of these values can often indicate the precise reason for the alarm condition A complete list of alarm conditions can be found in the appendix at the end of this manual 3 4 5 5 Using an inverter drive If an inverter is being used to drive the motor several additional precautions are needed The voltage frequency is expected to be constant within well defined limits for direct line driven motors but can vary considerably when an inverter is used MCM can handle the range of frequencies typical of an inverter but first needs to learn the motor at a single frequency representative of the conditions it will meet in practice The value of this dominant frequency must be entered from the Edit Settings menu If MCM measures the frequency to be out of the expected PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual range it will issue an alarm in both the CHECK MOTOR and LEARN modes and the user should
67. rminals on the MCM rear panel R phase to Vi S phase to V2 and T phase to V3 using the connectors provided Similarly the lp Is connections from the current sensors should be made to the appropriate current terminal pairs 131 112 121 122 131 132 on the upper part of the rear panel Section 2 MCM Installation NOTE It is not essential that all three sets of phases have the correct phase relationship as the phase ordering is determined by MCM The order of these voltage and current pairs is not important as MCM determines the correct ordering when CHECK MOTOR is first run on the device RS422 485 Communication Termianls Motor Current Inputs Hardware Reset Button Communication Indicator Assembly Bolt Supply Voltage Motor Voltage Inputs Ground Relay Terminals Connection Pin 2 5 1 Protection against pickup of electromagnet interference on the power lines In order for the unit to function within the harsh electrical environments often found in switchgear enclosures and to conform fully with emission standards it is strongly recommended that all attached cables be passed through the ferrite rings delivered with the product to their MCM sockets PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual NOTE A circuit breaker should be provided on the power line in close proximity to the MCM unit The circuit breaker should be clearly marked as the power switch for the device
68. rming ENTER Local Lockout and passwords Some modes can be protected for supervised access by setting the local lockout setting MENU Edit Settings Password Run Settings Local Lockout If this mode is set access to the following modes is password protected 1 CHECK MOTOR 2 RUN 3 RESUME 4 UPDATE In addition canceling any of these modes by pressing CLEAR also requires the user to supply a password All passwords are the same as that used to access Edit Settings 3 3 3 1 X First time use Before MCM can be used for the first time it is necessary to change various settings from their default values a table outlining the MCM settings is shown in the appendix Values relevant to the connected motor must be set for the quantities described in the following sections 20 Section 3 MCM Use 3 3 3 2 Calibration factors Hall effect current sensors and assemblies supplied with MCM should be accompanied by a calibration document containing the sensor s calibration factor The values of each calibration factor should be entered into the correct setting under the Calibration menu It is important that the correct factor be entered for each channel as MCM will not function correctly if the calibration factors are incorrect For channels connected to transformer sensors the calibration factor should be equal to the nominal ratio of the primary to secondary turns For example a 100A current transformer with a 5A output and a
69. rming a general reset 0x04000000 Cluster error An illegal cluster value was detected 0x08000000 Flash data error Data stored in the flash RAM is corrupted and cannot be used This error is generated during both learn and test modes following an attempt by the algorithm to recover from another fault 0x10000000 Stability error Clusters used by the algorithm are inherently unstable 0x20000000 Voltage range error An illegal voltage value was detected 5 1 2 Alarm Conditions Section 5 Appendices Alarm Alarm type Description Number 0x0001 Voltage balance Voltage phase imbalance exceeds the set threshold 0x0002 Current balance Current phase imbalance exceeds the set threshold 0x0004 Voltage range Ch1 Voltage greater than the upper threshold 0x0008 Voltage range Ch2 Voltage greater than the upper threshold 0x0010 Voltage range Ch3 Voltage greater than the upper threshold 0x0020 No voltage Ch1 Voltage less than acceptable No voltage limit 0x0040 No voltage Ch2 Voltage less than acceptable No voltage limit 0x0080 No voltage Ch3 Voltage less than acceptable No voltage limit 0x0100 High current Ch1 Current exceeds upper threshold limit 0x0200 High current Ch2 Current exceeds upper threshold limit 0x0400 High current Ch3 Current exceeds upper threshold limit 0x0800 Motor not running All currents were measured below their acceptable No curr
70. s 54 5 2 2 Line driven SYStOMS ccccccsessssscccecessseececcessssseceecesssseeseesesesssseeseesssseseeesssesaaes 54 5 3 Appendix 3 Connection Diagrams s ccccsssssssccecesssssnseeeessessseeeceesssesseeeesesssaees 55 5 3 1 Low voltage line driven motors with current transformers MCM LV Line 55 5 3 2 Low current 5 200A low voltage inverter driven motors Hall Effect Sensor amp MCM LV Inverter cott ettet tdeo rece penatib tr eee iun ite lan dice eds 55 5 3 3 High current low voltage inverter driven motors with current range of 201 2000A Hall Effect Sensor amp MCM LV Inverter sess 56 5 3 4 Medium high voltage motors with voltage amp current transformers MCM MV Line 56 5 3 5 Medium high voltage Aron connected motors MCM MV Line 57 5 3 6 SoftStarter d e ue rr tex ERRARE E e Ode ent opstara eda chosen atte 57 5 4 Appendix 4 Menu settings and parameters c cccccssssssccecessssssnseesssesstseeeeessssenaes 58 5 5 Appendix 5 Edit Settings Menu items esssessseeeeeeeeneennennenn nennen nnns 59 5 6 Appendix 6 Flowcharts for MCM use sseeeeeeeeeneneenen nennen enne nnne nnns 67 5 6 1 Running MCM Edit Settings and Check Motor esee 67 526 2 Running MEME LO Orn iii iore eiie torii dese cocos ve eto are aee edu eaae ce ce cepere pee o salad 68 5 6 3 Running MCM MONITOR IMPROVE UPDATE eene 69 5 6 4 Ru
71. s that a valid learning period is first performed before allowing the user to request the device to monitor the motor Alarm messages and status indication Alarms specific to the motor MCM divides warning messages into the categories of warnings alarms and errors Warnings inform the user that non critical conditions have arisen that the user should be aware of but do not affect the performance of MCM Alarms provide information specific to the motor being tested and are indications of faults caused Section 3 MCM Use by incorrect connections to the motor the supplied line voltage and or motor currents being outside the specified limits and other conditions that prevent MCM from correctly determining the state of the motor Alarms do not cause MCM to stop monitoring completely but generally are indications that there is something that needs to be investigated and possibly changed before MCM can function to its full extent In some cases an alarm may indicate a transient event such as high line voltages which although damaging to the motor in the long term do not indicate an immediate need for action Of course if the frequency of such events is sufficiently high the cause should be located and corrective action taken to remedy the problem NOTE It is important to realize that when an alarm is displayed MCM does not process the data taken from current and voltage channels Therefore MCM cannot monitor the motor status
72. single primary turn would require a calibration factor of 20 The same transformer with two primary turns would require a calibration factor of 10 A 6500V voltage transformer with a nominal secondary voltage of 100V would require a calibration factor of 65 NOTE Any channel connected directly to the motor without an external sensor i e voltage connections on low voltage units requires a calibration factor of 1 3 3 3 3 Motor settings Nominal voltage current and frequency The nominal voltage current and speed in rpm of the attached motor must be entered under the Motor Settings menu These values can be obtained from the motor specifications MCM uses these values to determine whether the motor complies with its specifications and incorrect values are likely to raise alarms The nominal line frequency or most commonly expected frequency in the case of an inverter should also be set Similarly the motor connection type must be set to one of Star or Delta 3 3 3 4 Communication settings Setting the device address If the MCM networking options are to be used the MCM network address must be supplied By default this is set to 0 which by convention is the address of the host terminal Use of this address will therefore disrupt communications over the network and must be changed prior to connection Any address between 1 and 255 can be selected although it is important to check that the selected address is not in use by a
73. ssing the Port Settings button at the top of the view This will bring up the Communications Settings window shown below Communication Settings COM1 BAUDRATE 19200 PARITY EVEN DATA BITS e STOP BITS 2 C TCPAP IP or URL PORT TIMEOUT 3000 msec Cancel There are two types of connection options that are available If your PC is directly connected to the RS485 RS232 serial converter via a serial port then make sure that Serial is selected and enter serial communication settings in the relevant boxes below The default settings are e Port COMI This depends on your PC s setup but most PC s have only one serial port which is addressable at COM1 by default e Baud rate 19200 e Parity EVEN e Data Bits 8 e Stop Bits 2 If you are going to connect to a remote MCM or MCM network using a TCP IP connection then make sure that TCP IP is selected and enter the TCP IP connection settings in the relevant boxes below These will depend on your network configuration PS 01 KL 01 REV 00 MCM Motor Condition Monitor Users Manual 46 When you hit Connect button Configuration utility will automatically try to connect to the default address of 1 and display the status of the connection inside the Connection Status box If the MCM has a different address select the appropriate address from the Address selection box Configuration utility should connect to the device and display its status as gr
74. st of its time in this mode monitoring attached motor systems NOTE In order to start monitoring MCM must first have learnt the characteristics of the motor it is to monitor and have a valid learning mode Iteration cycle time In general a data processing cycle takes between 60 120 seconds depending on several factors First MCM requires relatively unchanging data over a minimum time period during its data acquisition phase and will repeat the data acquisition until it obtains stable data thus varying the iteration time cycle If the amplitude or frequency of the voltage and current phases varies excessively and stable data Section 3 MCM Use cannot be found an alarm is raised Secondly if harmonic values are being calculated extra processing cycles are required Finally if MCM encounters an error it may repeat the cycle several times NOTE If the Local Lockout setting is ON it is necessary to supply a password before access to any learning or monitoring mode is granted Once started the monitoring process will continue until one or the other of the following conditions is fulfilled 1 Anerror condition is generated and canceled 2 The user presses the CLEAR button to cancel the process In order to prevent unauthorized access if the Local Lockout setting is set a password must first be entered 3 Power to the MCM unit is cut 3 4 5 4 Alarms during the monitoring process Ala
75. t cccccccesssssececesssseseeeessesssseeeceesssseseeeesessaeees 14 2 7 Installing with soft starter systems cccsssccccessssssseceeeesssseeecessssseseeeeesesssseeeesesaes 15 2 8 Installing with inverter drives cccccccccssssssceecessssececeescesssseeceessssseeesesssssnseeeeeees 15 MEM ELT T in aoee oneens aea e aa aaa EEE Soe 17 3 1 Introduction e enee eE i EEE Gia Ala AE eE A aE ETE tees 17 3 2 The front parnel 1 iren aaa ae tabi EEE ss EEE 17 3 2 1 Confirming ENTER and CLEAR eene nnne nnne n nnns nennen 17 3 2 2 Using the front panel buttons ssssssesseeseeeeeeeneee nennen nennen nennen 18 3 2 3 Setting numeric values sende eere e ENS Re a aaa dad 18 3 3 Configuring for Use eto ro eb eden st eet a dede nee eo eee Rene eda 18 3 3 1 Master reset ci eR I de ee RR EIN e n ne e a ER Po CHER RE edt 18 3 3 2 Entering the password eene nennen nennen nnn nnne nnns 19 3 3 3 The Edit settings menu ssssssseseseeeeee enne enne nnn nnne nennen 19 3 4 Running M CM 5 reete ta cua dei ee durer du HIE Po E32 TIRE Recon ede E A ee edades 22 3 4 1 Introduction eee nra e A eo e tete dea ashe e tex ee aee aetna eens 22 3 4 2 Alarm messages and status indication eessesesseeeeeeeee eene 22 3 4 3 Running CHECK MO OR 3st ai etus e aede epa totu ahaa actrees 25 3 4 4 Setting and checking the input connections esesesseeeenenenennnne 26 3 4
76. than the monitored motor When MCM discovers an error condition it makes several attempts to recover and only if these attempts are unsuccessful is an error message generated All errors stop MCM from functioning and must be cleared before proceeding further Errors are indicative of a serious problem within MCM and their source should always be investigated An error indication consists of two parts Firstly the displayed error string and secondly the associated error number When reporting device malfunctions please be sure to include both the message and its associated number Please refer to the appendix for a full list of error messages Viewing error messages and numbers MCM indicates an error to the user by the string Error on the first line of the display followed by the error string on the lower line Pressing the RIGHT or LEFT buttons will display the error number Canceling errors and performing a master reset NOTE Performing a hardware reset in this manner resets all settings to the factory defaults and all previously saved information will be lost This includes all learning mode and Edit Settings data so a hardware reset should be used only as a last resort Section 3 MCM Use Pressing the CLEAR button will cancel the error and return to IDLE in most cases If the error occurs during an error recovery operation it will not be possible to cancel the error in this manner but will require a full master reset
77. that the sensors are measuring the line rather than phase currents i e the sensor is situated on the line side of the contactor as these differ For star connections the two are the picture same If the amplitude of the R phase current waveform varies excessively MCM will not be able to find stable data and will give the unstable line alarm If the problem lies with the input signals it should be immediately obvious by inspecting the displayed waveform In the case of excessive variation of the R phase current amplitude the Current Instability threshold should be incremented from its default value of 1596 in steps of 596 up to a maximum value of 5096 using the MCM front panel If the variation exceeds this level please contact Artesis NOTE All phases should be checked for correct clean zero crossing If a waveform appears to be regular and sinusoidal over consecutive half periods but does not cross through zero it is likely that the zero crossing detection hardware is defective and the unit should be replaced If however the waveform is irregular the problem could lie with the sensors In this case check all cabling and power supply connections If these are satisfactory return the unit if the problem lies with 4 4 4 5 Section 4 Troubleshooting a voltage channel For current channels try replacing or swapping the sensor with another one If the new sensor does not work the problem is internal to the MCM un
78. uipment Faults and their diagnoses using MCM 54 MCM uses a model based fault detection and diagnostics technique In this technique the expected dynamic behavior model of the three phase system under varying conditions such as load is determined and compared with the measured dynamic behavior to monitor abnormalities MCM first learns the system for a period of time through acquiring and processing the real time data from the system The data is processed using system identification algorithms for the calculation of expected dynamic behavior and the model parameters The changes in the parameters of the system indicate abnormalities developing in the system Further processing of these parameters is used for diagnosis As opposed to traditional vibration and current signature analysis this approach uses a cause effect input output relationship and therefore is immune to the surrounding noise or noise in the inputs Also the difference between expected and actual behavior filters out and enhances ONLY abnormalities generated by the system which allows for earlier and more accurate warnings The expert system approach eliminates the need for a database or record keeping expert personnel time consuming data gathering and analysis It provides comprehensive mechanical and electrical as well as driven system fault coverage though it measures only voltages and currents Section 3 MCM Use MCM uses the electric motor of the equipment as
79. y is indicated The mechanical parameters M1 M12 correspond to the 12 maximum values obtained in the frequency spectrum These parameters are also used for diagnosis The frequencies at which they occur indicate the type of fault i e an imbalance loose foundation oil whip fan blades inner or outer race of bearing etc These parameters are provided to the user for trending and diagnostic purposes 3 4 9 Interpreting MCM fault indications 3 4 9 1 56 MCM status values MCM employs two different measures for calculating the motor status Motor Status 1 and Motor Status 2 In addition to these MCM also monitors load and line changes and summarizes the results of this monitoring via the Load line status parameter Motor Status 1 monitors the maxima of each of the three groups of parameters introduced in the previous section over a window with a default window size of 14 iterations in a monitoring mode and compares them with four different internal thresholds calculated following the initial learning phase Motor Status 1 takes values between 1 and 5 is calculated as follows Condition Motor Meaning Status 1 All medians over the window of the maxima of the three groups of parameters are not above the first threshold Section 3 MCM Use The motor is behaving as expected At least one of the medians over the window of the maxima of the three groups of parameters is above the first threshold T

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