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User`s Manual - Advanced Test Equipment Rentals

1. Field winding s temperature is below standard ambient 40 C or motor may not have warmed up yet Series elements of the field winding are not part of the circuit turn turn faults Nameplate vs Motor issue Error entering the nameplate when creating the motor Motor s nameplate doesn t properly represent the field circuit If the field circuit s resistance is lower than the nameplate suggests Possible Effects If the field winding has a turn turn fault and if the field voltage has noticeable harmonic components the shorted turns are being overheated The field s ground wall insulation will fail prematurely The amount of overheating due to the harmonic current content depends upon the amount of Vf_ripple Vf If the ambient temperature is below standard ambient 40 C and the motor has not operated for a long enough time then the field winding is still in the process of heating up If the drive does not change the Vf then If will keep falling until the field winding reaches a steady state temperature Many drives have motor models used to offer higher quality speed torque controls The field s resistance varying too much from the drive s motor model may introduce stability problems to speed or torque control f the motor s nameplate doesn t properly represent the field circuit The field s resistance varies too much from the drive s motor model which may introduce stability problems
2. g Number of Commutator Bars Be Has Interpoles no y Frame MINS Field Weakened Volts M2 Service Factor 1 00 Winding Shunt Enclosure ms Insulation Class a y Max Ambient Temp C jo lt Back Validate gt Skip Validation gt gt Cancel Finish Fig 8 11 Create machine nameplate a Number of poles 2 4 or 6 b Has interpoles Yes No c Winding Chooses between shunt compensated shunt or permanently excited d Insulation class A F B or H 2 24 2010 71 005 V2 EN EXP4000 79 DC software overview e Number of commutator bars This is display with an up down arrow that progress in multiples of 2 4 Required fields are listed in bold Yellow fields are recommended but can be left at default values 5 After all information has been entered click on Finish to add to machine to the list in the tree Note A DC machine can also be added by clicking on the icon on the top navigation bar Follow the remain procedure to complete the machine Right click menu items Within the navigation pane of the DC software there is a right click menu to help the user with a number of activities I C PTA 4 2 Open Database Ctri O Folder J Close Database Dc Machine i Database gt Yi Delete Del Rename Compact and Repair Grouped Style Open File Location Properties Fig 8 12 Right click menu Database or Folder View If located on a Database
3. Measurement Thresholds Vf Level 109 108 gt 110 00 And Up lt 1 iad 107 06 105 00 11000 3 8106 DE z 105 0 0 105 00 104 Vi Level Caution Waming 107 06 105 00 110 00 Date Time Print Close VE Ava 321 17 Va Avg 359 01 Rf Est 4394 vi 12 Close Fig 8 31 Field Voltage Level 2 24 2010 71 005 V2 EN 88 EXP4000 DC software overview Function Connecting Vf onto the field winding causes the flow of If This creates the magnetic field necessary for torque generation Typical thresholds Nominal Vf_field_weakening lt Vf lt Vf_base_speed Warning Thresholds 120 Vf_base_speed 80 f_field_weakening Caution Thresholds 110 Vf_base_speed 90 Vf_field_weakening Standards NEMA MG1 Section 1 12 64 DC machine VF troubleshooting Result Vfl gt Vf_base_speed Possible problem root cause Case If lt If base speed Field circuit s resistance is higher than nameplate suggests Field winding is running too hot Excessive contact resistance in the field circuit The field circuit s lead lengths cause additional voltage drop prior to reaching field winding terminals Error entering the nameplate information when creating the motor Possible Effects Contact resistances tend to increase over time Following this trend the worsening contact resistance will lead to over speed trip
4. Linear Systems Time Domain and Transform Analysis Harper amp Row 1987 ISBN 0 06 044925 Luke Signalubertragung Grundlagen der digitalen und analogen Nachrichtenubertragungssystheme Springer Verlag third edition 1988 ISBN 3 540 19435 5 Gabel Roberts Signals and Linear Systems John Wiley and Sons second edition 1980 ISBN 0 471 04958 1 Karni Byatt Mathematical Methods in Continuous and Discrete Systems Holt Rinehart and Winston 1982 ISBN 0 03 057038 7 Glossary of Terms Average Power Factor Average of three single phase power factors Clampons Split core clamp on CT s Clipons Clips for voltage pickup Crest Factor Difference between the sine wave peak and the RMS value 2 24 2010 71 005 V2 EN 139 EXP4000 References Current The time rate of flow of electric charge in the direction that a positive moving charge would take and have magnitude equal to the quantity of charge per unit time measured in amperes Efficiency Defined as output power divided by input power Electrical Model A group of Electrical thresholds EP External Port Harmonics Periodic motion consisting of one or more vibratory motions that are symmetric about a region of equilibrium as the motion of a vibrating string of a musical instrument Haystack Name of the NEMA guideline to Vibration Speed versus Frequency ina double logarithmic scale Horsepower A foot pound second unit of power equivalent to 55
5. Rated Current 106 15 Field Voltage Level 324 84 Arm Voltage Level 331 36 Arm Voltage FF 1 33 Arm Current Ripple 48 02 Arm Current Level 306 57 High Field Resistance 146 01 Low Field Resistance 233 61 Field Current Level 6 95 Load Level 0 00 Notes 2 24 2010 71 005 V2 EN EXP4000 Pass Pass Fail Pass Fail Pass Caution Pass Caution _ Caution Level 31500 00 52500 00 2 00 6 00 42210 00 110 00 90 00 687 75 100 00 33000 00 55000 00 3 00 9 00 44220 00 120 00 80 00 720 50 110 00 102 DC software overview Armature raveforms 0 0029 0 0059 0 0090 0 0120 0 0150 0 0181 0 0211 0 0242 0 0272 0 0302 x Axis 0 0029 0 0059 0 0090 0 0120 0 0150 0 0181 0 0211 0 0242 0 0272 0 0302 w Axis Fig 8 49 Sample report 2 24 2010 71 005 V2 EN 103 EXP4000 DC software overview 2 24 2010 71 005 V2 EN 104 EXP4000 Physical connections of EXP3000 Connection setup wizard 9 Physical connection of the the EXP4000 Connection setup wizard Connecting the EXP4000 Important safety information General Safety Precautions Note The general safety information presented here is for both operating and service personnel Specific warnings and cautions will be found throughout this manual where they apply Note If the equipment is used in any manner not specified by Baker Instrument Company an SKF Group Company the safety protection provided by the equipment may be imp
6. 143 Technical specifications Current Transformers AC Range 3000A Insulation 600V RMS 600V RMS 600V RMS 1000 V Jaw Opening 20mm 20mm 57mm 8 in 0 1 to 0 5A lt 2 5 0 1 to 1A 2 0 R 0 1 to 10A lt 3 1 of R 0 1mV 0 2mV 0 1A of R Reading 0 5 to 1A lt 2 5 10 to 80A 1 R 10A lt 3 of R Accuracy R 0 2mV 50A lt 1 5 of R 1to10A lt 1 R 80 to 150A 1 5 R 2004 lt 0 75 of 0 2mV R 1000A lt 0 5 of R Weight 3 180g 3 180g 3 x 550g Dimensions 139x51x 139 x 51 x 30mm 111 x 216 x 45 30mm ea ea mm ea Current Transformers DC a S008 100A 10mV A 600A 1mV A 7500A 1 5 V OA 75004 Overload Red LED indicates 2000 ADC cont up overload to 1 kHz 600 V Accuracy 50mA to 104 3 of 60A 1 5 reading 5OmA 0 5 to 40A 1 5 of 500mA to 40A 4 reading 0 5A of reading 50mA 40 to 60A 1 5 of 40A to 1004 15 reading max 100A 600A 0 5 to 100A 1 5 of Reading 1A 100 to 400A 2 of Reading 400 to 600A 2 5 of Reading 4 25 lbs Dimensions Connectors AC DC Voltage Port 1 Cannon Jack AC DC Current Port 1 Cannon Jack Standard 110 230V EP Vib Port 2 24 2010 71 005 V2 EN 144 EXP4000 Index A Acquire EP 37 41 Assign Elec Test Model 42 C Channel 44 Connecting 105 Continuous 46 Create Elec Test Model 42 Create Motor 37 Create Vibr Test Model 71 Current Clamp On 144 Current Unbalances 17 24 D Databas
7. 4 Patter Difference i Pattern Difference HO mnn mw ent Core Fig 1 8 Oe condition test within the machine performance domain 2 24 2010 71 005 V2 EN 21 EXP4000 EXP4000 Tests Efficiency Efficiency is the ratio of mechanical output power of the motor to the electrical input power This can be expressed as j 100 Ploss j Pin Where Ploss the power that dissipates mainly heat Pin input power Ploss can be seen as the energy in the power bill that is potentially wasted and degrades motor health The efficiency test displays the motor s operating efficiency and previously measured motor efficiencies Low results in the efficiency test suggest that motor retrofits may be advisable A decline in efficiency may indicate an increase in the motor s operating temperature causing faster motor degradation A manufacturer database with more than 20 000 different motor designs is provided This database compares existing motors with similar designs that perform at or above EPAct 92 These motors are compared with respect to current operating load point and their resulting efficiencies If the efficiency of the motor under test Is significantly lower than the target efficiency found on a EPAct motor a warning or caution flag Is issued Note If an efficiency warning or caution flag is issued the following steps should be taken 1 Check that the correct stator and lead line to line resista
8. ee ecescsscsscssecssesecsecseesscesecseeseeeeesees 29 fas 6 ANG G 02 BUC AA RN E E RO OEE OO ER TE EP PPO nO ONE OE eR Pe 29 Database TORI leds 29 Navigating through the software Mtra cd 29 EAP SOU So Ware SHeciie Te CIES ns AS A ad diaedlaiake Gude 29 Grey shaded MS is A el 29 o 6 e NEETA A A AA EAS EE ATAA EEEE AE AAE E IENE T 29 AO WS OIC WIT COW SCO INS aen AE E AE E 29 O RN SR 30 SARNE SOUL WV AT ae cect asa nets wre A A acetates ened ace nuiseunaser N 30 Nunca Nc Tod 31 MA A A A EEA E 31 RESET A AA AE sala 31 TESTO DANG liaise tas Ae OS 32 Software navigation MAN Macas iii 32 Icons Displayed within Machine Trias taa 33 Upgrading databases from previous software versions sesessessesessesreseesesresresesresresesresrereesesree 33 Pronte r conio aO O 33 Sa SNOT A ON 33 A EN 34 ii 35 Basic Software OEI Wi ej 35 RS A II A A iss E T EET 35 E EAREN EE E ste AT AT OE EO AE AEAEE EA NA O 35 AA PP E T REO A 35 PERCUMA ODO O A E AA 36 PEDOT an a A E ANE aectgaiseineec ious aaseaseaeen etade ue neiaeaaat 36 E EE AESA VOTE E A 3 Miatciine Mena EN ar tent ee a ote tr TR G 37 MAINE o AEA 38 ERE ALE STAC MNE ari AS AAA ANN 39 Namme Dt ina 39 PVC MIG Ole Melt TS ease 39 Machine mi orma O ena Ains 40 Motor design Eneroy NOOO rt caia 40 EMMA MS else 41 PR Rin gre leinl nl ccrnmere ret team tne or ere nr yore nent etn A en Tay RRO ED hee Aen ar Ret Rr ae 41 Acquire EP senal NUn Dr aaa 41 ME a UOC AP TR EEE anna asute aden OTR 41
9. 500 570 1 1 a 1 in i Aa ret 1 1 AES 17 5801 00 25 50 75 100 125 150 175 200 225 250 275 300 332 Time msec Fig 5 5 2 Waveforms Waveforms In VFD mode voltage and current for the phase a is shown 2 24 2010 71 005 V2 EN 60 EXP4000 VFD sosftware overview VFD details domain In VFD mode this window displays the dynamic behavior of voltage level torque frequency and speed as a function of time As with any panel within the EXP4000 software clicking on the zoom info panel will give the user a number of options to zoom or pan specific areas of each screens Printing the screen is also available man ce ce a anda T YTD Metalla Fig 5 3 VFD details 2 24 2010 71 005 V2 EN EXP4000 61 VFD sosftware overview 2 24 2010 71 005 V2 EN EXP4000 62 6 Continuous monitoring software Continuous monitoring streaming The CM3000 continuous monitoring software evaluates important operating values of a machine application including triggered acquisition and recording It acquires 11 samples per second on 41 parameters The graphical user interface can be rearranged during operation to suit the particular analysis needs If recording it stores all available File Machine Tools View Options Help CHO x Database Mot nal Machine CT_BAD_ROTORBAR VA RMS V VB RMS V VC RMS V 2 00 400 6 00 g 99 2 00 4 00 6 00 g 99 2 00 4 00 6 00 g 99 0 00 E 10 00 0 00 10 00 0 00 10 00 0 00 0 00 0 00 Y
10. Aa Motor Master Options Fig 8 19 Tools Menu see If it is working within prescribed tolerances Options There are three different types of options with this menu These options allow the user to customize several database features General options Within the General options set the calculation path to locate the calculator This will allow access to an online calculator Currency can be set from here The default Is in USD 1 Type in the currency that is appropriate for the region User Options x General Database Archive m Calculator Path Browse M Currency Currency Name Currency Symbol Dollar s v Default kwH El 0 010 Units US v Display Style Default Cancel Fig 8 20 User options General options 2 24 2010 71 005 V2 EN EXP4000 DC software overview 2 Select the currency symbol from the drop down box that represents the money chosen 3 Set the kwH price to help calculate efficiencies and cost savings 4 Select from the drop down box the equivalent unit of currency either US or Metric 5 Screen colors can be changed by clicking on any of the color schemes listed 6 To save changes click Apply and then OK Database The database options menu allows the user to set the location for the database files and to set what type of database is to be used as the default The user can select from user option
11. EXP4000 sofware specific features Grey shaded fields Gray shaded fields are generally not editable Fields with white backgrounds are editable Text fields Text fields are areas that contain editable words or numbers To edit text fields press or click in them and type The software will prompted the user for missing information required by the EXP4000 if a necessary field is left blank This is generally in the create motor or edit motor panels Arrows and Windows icons In the EXP4000 arrows serve two functions They allow the user to access information that does not fit on the screen or allow the user to change numbers in a text field For 2 24 2010 71 005 V2 EN 29 EXP4000 Getting Started example clicking on either the up or down arrow can change a caution threshold for the voltage unbalance test in an electrical test model Numeric Fields The two types of numeric fields are input and display The input fields are required to calculate portion of the result panels or allow entering additional information to the reports All other numeric fields are display results Starting the software To start the EXP4000 software click on the Explorer icon on the desktop or click on Start navigate to the Baker Instrument folder and click on the EXP software 14 a gt 8 Pu Explorer E ala Elo Machine Tveshokis Took dptons We Y r 1 H default NP Speed 1725 2 Elec Model default elec 2 Database Temp HP 0 50 Z V
12. Table of Contents Choosing a Sulttable oca von Or MER ads 133 Choosing a suitable location for the paella A 133 Current rans ormar C C Onec ons i aise al a A eh act a 133 voltage CONMECUONS sia id aio 134 Electi al L OnE OTS seats ei e EA RALES AREAS O o 134 METIEICALION ON Stalin Nada 134 OUEN cados 134 ER UNS ad sa 134 APPENA E OR O 139 REC ONCES ass 139 AGU SON R OPEN CINC ES riada notado 139 GIG SS AY Ol TETINE a A AAA Ai 139 ADDENOIX F anriirrnosares nia a AATTEET A A 143 Technical specificat ONS acia 143 O AET E E E A 145 2 24 2010 71 005 V2 EN 12 EXP4000 Preface Important safety information General Safety Precautions Note The general safety information presented here is for both operating and service personnel Specific warnings and cautions will be found throughout this manual where they apply Note If the equipment is used in any manner not specified by Baker Instrument Company an SKF Group Company the safety protection provided by the equipment may be impaired Safety term definition DANGER Indicates a hazardous situation which if not avoided will result in death or serious Injury WARNING Indicates a hazardous situation which if not avoided could result in death or Serious Injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE This signal word addresses practices that could result in property damage but not person
13. Torque in Newton meters Load HP Load in horse power load kW load in kilowatts Load Percentage load Va lf Percentage of synchronous speed equivalent Parameters Waveforms can be zoomed into display cycles Zoom in Shift and hold left click button then drag box around area of interest Zoom out Ctrl and right click button will return screen to original zoom level Practical data resulting from the Waveforms Firing sequence Fining angles determined by amplitude of waveform o Broken SCR extreme firing angle Input voltage unbalance Phases may be off lack of symmetry in waveforms 3 phase 3 3 SCR switching symmetrical waveforms unless too much ripple is present Typical DC drives will not have a flat waveform due to six pulse rectifiers or lack of ripple capacitors Rule The field circuit does not interact with load All load related signatures will make it into the armature but not the field Bottom Main Screen Aun Electrical gt View Connections E xit Fig 8 27 Bottom of Main Screen Run Electrical Click on Run Electrical to run programmed tests View Connections Fig 8 28 View Connections The view connections window gives a real time look at Input signals Va Vf la and If are displayed in terms of average RMS min max peak to peak and percent of 2 24 2010 71 005 V2 EN 86 EXP4000 DC software overview nameplate The graph sh
14. TIFESADAS MU oia 41 o A EN UFO SS ne ESE 42 Create elec esto li a 42 E A A A A A 43 Delete test moi A A 43 O 43 A TN tines 43 MEW CON NECIOS el 44 Mi ON 45 ae A A E A SOIT 46 Stator resistance es ii a 46 MOTOS do EE 47 EEEE OE E AEA A AAT AEE TEE 47 A ON 48 MOS ENOTE Data AAN AOS 48 Override Dee 49 Eleciricalacgu ition DOOR A O E A ANO 49 Spectrum acquisition OPUS sees hiret ne a Ee ia EE EAEE E E 49 2 24 2010 71 005 V2 EN 8 EXP4000 Table of Contents PEC acqu is IO nO DOS ii aca 50 Paco us OOOO rta a ada 50 BE E 50 MEE IR a 51 By TEE E E E A INE EE N E E E E E E T E E O 53 TORQUE software OV rvie W iaa 53 P50 OU tordue anay S SO Wa td 53 Spectrum domain demodulated spectrum option uu ccecccscscssecsecsscsscessesscseesscssecseesscsseseeeasens 53 DEmoalle ted pc UM daa OS A A O se Naeaaus vec ARE 54 A A A IN 55 Re Keltica ollen E pa AIEEE ETEA O A RIA 55 RON CUCK MN ai A 56 DI ias 59 WE WD SOWA Coc ccaasssesseotecarasvatscteuceceacucdacessawuais svete eboues ta cdanw E 59 VFO OOO WED analysis SO Ui ey urraca tal endian ton 59 A NI 59 A Reiland lta hilt tiesto aad ineateaebsindtas 59 PRI OS aaea A A E T II etal 60 WAVE OMS SES EAN A 60 Vi A numer a Petr etnet IN net BATE TET Bit Pps Per NEN RRO ene ET mn BOR FIST oe MORES Ine 61 ias 63 Continuous MONILOMING SoftWare colada 63 Continudusmentornng SUeanN IG as 63 A E AE E aceon tecinaess 63 Machine a A A Sa MCR gn EID ONE SRST YN RR SRDS ER NO 63 MAC
15. kabel om egumen eee E E ERA 115 Other Important oalet WAI a A 116 Operational Safe Wain aa i a a N AAN R ERA 116 MOCO TONCO MO Ee a EE AAE A E A A TORR CRONE A AEA 117 OKA Gathered Gata serein er A E AS 117 POINTS ENG Darme Sa E Dose A oes 117 Otherad A A EEN ENA 118 Looped acquisition Timed acguisitioN essiri rere entre se iE RE EEA 119 Creatina reports Tom the reno tener 119 Viewing annotating and printing reports eeesessesessesseseeseesesresresesresteresesrenresesresresteresreseeressesrest 121 ALO MANIC GENIE ra ONO WS ONS ri d N E A 121 Printing reports directly from results panel single rePOrt ccccccecsscososonoscacescessoscecsesensovesssouons 121 EMEC repor N Onn Une Sinn AUG sanas 122 ADUCE aes ee 123 Default SCOUTS aa 123 O o E cacao paassaanlaramsa uueionaniads 123 APENI O O tascsses suwseaseues Uensaue ence ua E ene E 125 Troubleshooting is sos dino 125 Bic ah qievetd e age ge iell c a elod gle Aida 125 o A O O O 125 NON VETO rn ETA ARA 125 ErEqUenN UY Asked UE ida 126 ADUCE aa amis 129 Blue TESUILS aia A A 129 Conditions under which test show blue Tesla bi 129 TREO 131 EPTODO Stal lA ON acusa da 131 Wae OO Snes ias 131 A A dod vaudases darned aves ssudendsondevesusesen dossoadavastaseeronaahton 131 Matenas 21 a 0 paper eee pen er Oe TACO 13d Sale Precautions TO ER mstalla tiOn seasea E NN 132 Installatiomsatel Warno Saen ni A E EEA A 132 Hardware Mot ON AEA 132 2 24 2010 71 005 V2 EN 11 EXP4000
16. 15 Accessory neerconnecionr oi 15 EAA UE A CATION Maida 15 Aa A A A 15 Installation Teorema do 15 SEa MC g E A E E E E 15 PONOT E a AA 15 Environment conditions istorig E ea a da 15 URAC ahe UNA EEA 15 A II E NE 16 IO CIN 17 EXPAOOO ess iia AA 17 Test domane Stnd ic dais 17 FEE ONS E A AAE E A A 17 OWE FUE OA N E E a a aa 17 Votos Lavel TESE y AIRES RANA ETEEN 17 VotageUnpalantce TEST Ninen E iaa 18 MIO IG O Or O rA A A A A N 18 Tota BLS AA A a E aR Seen 18 POW anar is chs Gd las a a EAEE EE 19 MES ls A E NAET 20 Vacmnne penrormance UON a Mir earra meen ao 20 A A A E E A OE AN 20 O area taas 21 Operating COCCI OI esrara O AN 21 o A saccton estates bathe N test eaten ekania ven nanae tain namcuna 22 FOG Ieee PIO Chases AEA 23 AAN A TAANS 23 UGH GLU a a ee arene tee etter ads 23 Current MIDS NES Ni cate dali hea cada meetin ceda 24 POE Me A e detest wis TE 24 Rotorbar Operando CONGO oli entienda carne cael gle 24 A A SST a WING ACC tt ia tl a a eal a er aN aaa aaa 25 A tin 25 COMME CUOMO MMI il O lisa 26 A itd Gale mate anil Sunset Si ni ca Riehl ath AN tlt ON Role Cattell 26 ABC S YMC 0 a a eee ener ner mir Petre nen E ae ete ee eee oe Ce Ck Pe ae 26 RA a a ie dos 26 Declara oO CONO sra aida a 28 Di 29 COtuna tarta a dois 29 connoarno software Tor motor Uan AE O E dae 29 Database Manageme RE A A oia 29 2 24 2010 71 005 V2 EN 7 EXP4000 Table of Contents Consequences of not organizing data into databases oo
17. 24 2010 71 005 V2 EN EXP4000 7 V position 44 V I Spectrum 25 VED Details 59 61 121 Vibration 43 71 72 123 140 141 143 Vibration probe 143 Voltage Clips 143 voltage unbalance test 30 31 W Waveforms 17 26 30 61 146
18. 35 AM elec af 10 28 2004 11 34 08 AM elec af 10 28 2004 11 34 08 AM elec af 10 28 2004 11 33 41 AM elec af 10 28 2004 11 33 41 AM elec 4 10 28 2004 11 32 58 AM elec af 10 28 2004 11 32 58 AM elec Ma Motor H 4 y 10 28 2004 11 51 38 AM elec af 10 28 2004 11 51 38 AM elec af 10 28 2004 11 51 11 AM elec af 10 28 2004 11 51 11 AM elec af 10 28 2004 11 50 44 AM elec af 10 28 2004 11 50 44 AM elec af 10 28 2004 11 50 17 AM elec af 10 28 2004 11 50 17 AM elec Y 10 28 2004 11 49 50 AM elec e 10 28 2004 11 49 50 AM elec Fig 3 5 Machine tree Fig 3 6 Machine tree view MN Machine Tree mel Le Ey Database View Options Desktop E B My Documents 9 IBM_PRELOAD C 3 HomebDir on Baker SryD1 H 3 Library on Baker Srv01 L 3 Engineering on Baker Srv01 N 3 Sales on Baker Srv01 5 3 Utility on Baker Srv01 U Se Tmp on Baker Srv01 W SQ My Network Places S db e 10 28 2004 11 49 50 AM elec a mm mm Cancel f kd q_z___ _ e P Fig 3 7 Machine tree options section 2 24 2010 71 005 V2 EN EXP4000 Mase Pla shi am 38 Basic software overview Create machine The Create Machine option generates a new machine ID which is required to run electrical or vibration tests The Create Machine properties panels have four sub panels or tabs The Name Plate and Machine Information tabs will remain red when required information is needed All fields in red must be filled
19. APE EEA AO Jy VEO edo 98 DEC AAA SAS ARIS A ANO DA 98 E E EE E mieb cbse waned ax A A E E RA A 98 A E dades 99 Torque Special AAR 100 O ION 100 REO o 101 ia 105 Physical connection of the the EXP4000 Connection setup wizard ccccsssssscecseessccceees 105 Conpectina tie EA AOOO nadar 105 daneo nn a e E AEA E E 1AE Saa 105 General Sal Ly Preciado iria EEOSE AE AE 105 2 24 2010 71 005 V2 EN 10 EXP4000 Table of Contents FIENNA Olle ary PAIR OPUS EN E O ead T 105 SVC Labels tea nenas 105 Other important SA TES WV aN MUNG S aio 106 Operational salet Warning S asocieca iii 106 Physical Setup of EXP4000 with portable SENSO atari is di ia 107 To commect the EXPEDIA USOS 107 To connect the EXP 4000 to the motor terminada ia 108 Physical Setup OL the EXPEDIA os 108 Byicvere alintcvei a miclavg pica EAP AOOO eta 108 Conmmection setup MZ 108 Aaien ne SING NSS E e E A ESA E T TIPET ER E AAE are E E S E A 108 Usma tHe setup WI an 109 Trounleshooimd ENCON CONS near dla 110 E dais 110 ROS ONTO O O eaa a ao id iia 110 POS SIDE TES Maia A TE 110 Wie o A EEE OE ETRE 111 IWO CT SOU OM i NN n T A E 111 Mantaly AT SCM Nas Sa a a E aE ETA A 112 E i O EE E E E E Mere E E E EE E E EE E E N 115 Example test and report generation essessessseosecsecsseosecseesseosecsecoseosecoeeoseosecoseoseosecoeeoseee 115 MDOT ane sale MOM O Mei a A E AT 115 General al e Precaution AEE TOE T A A A a 115 SA A NE O E EEE AE TE T 115 5 mbols
20. Avg AMS V vs Time sec l AMS A IB RMS A IC AMS A 299 400 6 00 apo 299 4 00 6 00 y pa 299 400 6 00 apo 0 00 10 00 0 00 10 00 0 00 10 00 0 00 0 00 0 00 Avg AMS A vs Time sec 0 BS 10 15 20 25 30 435 40 45 50 55 GO 65 70 75 80 85 20 95 100 Fig 6 1 Continuous monitoring main panel channels not only the ones displayed A large number of independently operating triggers can be set and the stored data can be viewed File menu The file menu is directly linked to the main software of the EXP4000 The user can create a new database Ctrl N open an existing database Ctrl O close an existing database or exit the program Stream File Machine Tools View Options Help Database New Ctrl M Exit Open Chrl o yg Glose Fig 6 2 File menu 2 24 2010 71 005 V2 EN 63 EXP4000 Continuous monitoring software overview Machine menu The Machine menu is also interlinked to the EXP4000 main software Stream File Machine Tools View Options Help Machine Tree F2 Sl Create Machine Ctrl M Edit Machine ctrl E El Acquire EP Serial Number Reset EP Serial Number 0 Fig 6 3 Machine menu The user can open the machine tree F2 create a machine Ctrl M edit a machine Ctrl E acquire EP serial number or reset an EP serial number The gathered information will be recorded to the database Tools menu The tools menu allows the user to access the scope Ctrl S
21. Measurement Thresholds i Va Level a gt o 2 110 00 And Up E 2 105 00 110 00 4 E DEE x 0 0 105 00 18 a20 PRI 359 01 Va Pros Va Level Caution Waming 71 80 105 00 110 00 Load X 62 33 Vf Avg 321 17 Date Time Print Close Print Close Fig 8 30 Armature voltage level 2 24 2010 71 005 V2 EN 87 EXP4000 DC software overview Function of Va Armature voltage level is the main variable to control speed It is always created by the drive speed varies proportionally to Va e To change speed change Va e To reverse direction of rotation reverse Va k Va la x Ra Speed if And Synchronous Speed Typical threshold Nominal Va_Nameplate lt Va lt Va_Nameplate Warning threshold 120 Va_Nameplate Caution threshold 110 Va_Nameplate Standards NEMA MG 1 Section 1 12 64 DC machine Va troubleshooting Result Val gt Va nameplate Possible problem root causes Drive settings and motor nameplate data do not coincide Drive or sensor problem Malfunctioning control circuit or feedback Neutral plane is off Possible effects Operates over rated speed motor Brush fire Excessive brush sparking due to armature over voltage Commutator brush damage Field voltage level Vf Field Yoltage Level m oj xj Results Test Log Field Voltage Level 5 x Results TestLog 110
22. Options Daq card settings This option is a built in advanced debugging tool which changes the operation of the EXP4000 Please call Baker Instrument Company an SKF Group Company for further Information on its usage 2 24 2010 71 005 V2 EN 50 EXP4000 Basic software overview Display options The display options menu item allows changes to the looks of the EXP4000 software The first field switches between the U S Customary and Metric modes The differences lie in that U S Customary prefers Hp and lb in for output power of the motor and torque respectively while the metric system chooses to display kW and Nm for the same physical quantities The currency ring can change between displaying and for the monetary values The last field allows switching between displaying phase voltages to line voltages U S Customary vi Currence Dollars vi Voltages Line to Ground vi OK Cancel Fig 3 31 Display Options 2 24 2010 71 005 V2 EN 51 EXP4000 Basic software overview 2 24 2010 71 005 V2 EN EXP4000 52 4 Torque software overview T3000 torque analysis software The T3000 torque analysis software allows the user to access the torque domain If enabled the torque domain supplies the demodulated spectrum torque ripple and torque spectrum Spectrum domain demodulated spectrum option Demodulated spectrum With this software the EXP4000 calculates the 3D demodulated spectrum of the torque si
23. Ripple Load Efficiency 1747 9 14 90 98 7 75 0 Test Value Caut Level Warn Level Status Dig Voto Good Voltage Unbalance Good Ham Dian os 7o aon Gee Total Distortion Good Es Caent Good PA 0o now 12500 Good id Good e owo 200 300m Good j peones N A pa N A T Main Panel Energy Assessment Power Condition Report TT Machine Performance Report FF Machine Condition Report Load Reports l Cancel Fig 3 2 Print Summary Report Screen Assessment Machine Performance Report and Load Reports These items will print the panel page for that specific test Reports The reports section offers the ability to customize reports to see multiple tests with different filters and trending options The Filter On option provides report parameters for Show Good Results Show Caution Results Show Warning Results or allow a Date Range to be used to pick tests for the report Options under Select allow the user to select report parameters for All All Good All Caution All Warning All Warning and Caution or None 2 24 2010 71 005 V2 EN 36 EXP4000 Basic software overview Trending parameters can also be added for more value in reporting The trending options include All Machine Results Selected Results Only and Plot Mode Plot Mode also includes Line and Point Line Filter On Select Trending On a MotAnal H E BASEMENT 2 07 44 CLASSIC PROBLEMS C
24. Total Distortion Power Harmonics Machine Performance Effective Service Factor Load Operating Condition Efficiency Payback Period Current Over Current Current Unbalances Spectrum Rotor bar V I Spectrum Harmonics Connection Waveforms ABC SYM Comp Phasors To view any of these tests click on the associated domain and then on the associated test Many of these viewable panels will have results and test log views Power quality domain Voltage Level Test Identifies over and under voltage conditions Compares measured voltage levels with user defined thresholds fox ols Options Help NP Speed 1725 Volts 230 HP 0 50 Amps 2 10 Aur Mo y Voltage Level A oh nasesneansensnsnenned Measurement Over Voltage Over Voltage 24 00 20 00 15 00 10 00 5 00 0 00 Phase Phase B Phase C Amplitudes 1335 1355 1345 Average L L 2330 Rated LN 1328 Rated L L 230 Fig 1 1 Voltage level test within power quality domain 2 24 2010 71 005 V2 EN 17 EXP4000 EXP4000 Tests Voltage Unbalance Test Examines the single phase voltage in the motor by calculating its percentage unbalance via NEMA derating Compares the voltage unbalance level with the stored threshold A non balanced voltage condition causes negative sequence currents within the stator resulting in excessive heat The voltage unbalance test det
25. Y Imbal IA Angle deg IB Angle deg IC Angle deg VB Angle deg VC Angle deg 100 00 ZA Angle deg o ZB Angle deg ZC Angle deg Z Angle Avg deg Power A kW Power B kW Power C kW Total Power kW PF A PFE PFC PF Average Frequency Hz Power Out kW Torque N m Speed RPM Percent Load App Power A kVA App Power B kVA App Power C kVA App Power kVA Reactive Power A kVAr Reactive Power B kVAr Reactive Power C kVAr Scale Reactive Power kV Ar Channel Y over F Time sec Fig 6 12 Parameters 5 If the move option is chosen a hand will appear over the gauge or graph that was right click upon and this item can be moved to a different place on the screen 6 To set the new location left click 2 24 2010 71 005 V2 EN 69 EXP4000 Continuous monitoring software overview Channel description IA RMS A Root mean square of the current through the phase A CT in amperes This number AA will typically be between 30 and 110 of nameplate current Root mean square of the current through the phase B CT in amperes This number will typically be between 30 and 110 of nameplate current Root mean square of the current through the phase C CT in amperes This number will typically be between 30 and 110 of nameplate current VB RMS V Root mean square of the voltage B in volts Root mean square of
26. adjusting phasors Manually adjusting the phasors can quickly become confusing If the Suggest button does not provide a solution or if there is not a unique setup then manually adjusting the phasors may be needed Adjustments are exactly the same as adjustments made in the MCC in order to properly connect the EXP4000 There are two rules in adjusting phasors 1 All Phasors currents and voltages should have an angle between them of 120 degrees 5 2 For all induction motors the current phasor must follow the voltage phasor by a maximum of 90 degrees 2 24 2010 71 005 V2 EN 112 EXP4000 Physical connections of EXP3000 Connection setup wizard Fig 9 7 is a diagram of all phasor positions All three current phasors must be in the same area in order for the setup to be correct For example if the la phasor is in the high load position lb and Ic must also be in the high load position The dark shaded are non phasor positions Although this can be done mathematically no phasors can physically reside in the dark shaded for three phase Induction motors without PF correcting devices Va Fig 9 7 Phasor Diagram There is the possibility that phasors can reside in the high load position or be rotated 180 degrees and be in the low load position In order to minimize potential errors we have provided a load estimate If the phasors are setup in the high load position and the load estimate is 300 percent or higher then the most li
27. an existing or repair a database along with creating a backup restoring a backup or synchronizing a database folder The filter mechanism allows the user to find machines with no tests with a good rating with a caution rating with a warning rating or by date of test The Options menu offers the ability to browse other drives on the computer to locate databases available to the EXP4000 software Two options are available from this menu Set database directory or Set archive database directory x Machine Tree Jog eee O Database View EE Machine Tree a EJ Database view Options aveforms J Y Show Machines with no Tests ShiFt FS Show Tests with a Good Rating CtrHFS Show Tests with a Caution Rating Y Show Tests with a Warning Rating Filter Tests by Date E test Ej tes Filters KOWACO E E KO Refresh Basement E Reload Alamo i We default Me default Je Motor 7 Me Motor 7 af 10 28 2004 11 37 45 AM elec af 10 28 2004 11 37 45 AM elec af 10 28 2004 11 37 18 AM elec af 10 28 2004 11 37 18 AM elec af 10 28 2004 11 36 51 AM elec af 10 28 2004 11 36 51 AM elec af 10 28 2004 11 36 24 AM elec af 10 28 2004 11 36 24 AM elec af 10 28 2004 11 35 57 AM elec af 10 28 2004 11 35 57 AM elec af 10 28 2004 11 35 29 AM elec af 10 28 2004 11 35 29 AM elec af 10 28 2004 11 35 02 AM elec af 10 28 2004 11 35 02 4M elec af 10 28 2004 11 34 35 AM elec af 10 28 2004 11 34
28. are to be connected to the PTs the following way a Three phases are to be connected to the hot secondaries 120V typical and to the ground respectively 2 For medium and high voltage motors the Baker CT donuts are to monitor the secondary of the CTs 5A typical in the MCC 3 For monitoring of VFD motors the electrical connections are to be made between the motor and the output of the VFD 4 In any connection above the EP MCC cable is to be connected to the DB25 of the EP1000 The other end of the EP MCC Cable is to be panel mounted to the exterior of the MCC 136 2 24 2010 71 005 V2 EN EXP4000 EP1000 installation 3CT 2PT Connection Scheme Ib To Motor s Ic Pe CTS Va A A f j A A O rms Current display II LA p Currents Voltages le Ib la Ah Ve Vb Va Me F EP1000 A Medium or high voltage Db25 ee e PT and CT low voltage circuit in MCC aso A Ca Seles Connection of EP1000 From Source lt i rms Voltage display 157 2 24 2010 71 005 V2 EN EXP4000 EP1000 installation na m a m 2CT 2PT Connection Scheme From Source Ve PTS P7 SATa f A A H lio a A 7 b SAO OS eh a OWN Ls pee _ a E a ae a i REE NEE A NE EREE E A E Sti rms Current display i T g E rms Voltage display Currents Voltages lc Ib la gt Ve Vb Va pa d EP1
29. good data because of a set amount of tests that must be completed prior to the Instrument stopping It is recommended that a minimum of 5 tests be done with 10 being an optimal amount Tests Complete 0 Remaining 0 Start Close Fig 10 6 Continuous loop acquisition Any Timed Loop Acquisition xi Current Date Current Time 04 07 2009 o1 20 27 P Run Electrical wi Testis Every ej 0 Minutes T Starting Now O Ending When Stop tt Y Start Fig 10 7 Timed acquisition The second acquisition mode is timed This mode is based on time and date as the trigger Creating reports from the report generator Only machines with a stored result can generate a report User can select multiple machines and results to generate a report 2 24 2010 71 005 V2 EN 119 EXP4000 Example test and report generation Select the results to be included on the report by placing a check next to the result in the tree machine summary page Is automatically generated for each unique machine that is being included in the report Click on the Filter On tool button to toggle filtering of the results on and off Select Results 4 J x Filter On Select TrendingOn a H Mot amp nat H BASEMENT i Y CLASSIC PROBLEMS EL Sh CLASSIC PROBLEMS H M4 BAD_ROTOR_BAR H O Ya CT_BAD_ROTORBAR_1 H Ha INCIPIENT_ROTOR_BAR cL LOW_EFFIENCY H MILD_ROTOR_BAR HC M4 OVER_CURRENT Y OVER_CURRENT
30. in Hz enables switching the x axis scaling from and to Hz or KCPM 1 000 CPM settings The last choice of this sub menu allows to chose between Mask Electrical Freq to Unmask Electrical Freq settings Masking electrical Frequencies effectively cuts the peaks in the frequency spectrum which are caused by the known electrical fundamental frequency This setting erases the saliency of the electrical fundamental peak and its harmonics The Zoom and Restore options cover the identical functions as the Zoom and Restore buttons of the Spectra panel i Bearing Frequency Markers X Company JAFBMA Model oco o mo ooo M73 Mak Hamonics i To Ha k BFF 733448 Mark Harmonics io Ta il fr BSF 7695822 Mak Hamons Hi To Ha Side Band Freg pa Side Band Frequencies to Mark E 4 A mam la Select Bearing Fig 4 6 Bearing frequency markers Frequency markers allow the addition of bearing frequency information To set the appropriate bearing frequency click on frequency markers and then select bearing From the drop down lists choose the company and model number of the bearing If the bearing Is not available click on create bearing Input the needed information If the BPFO BPFI or BSF frequencies are not known click on Estimate Frequencies and input the number of balls the bearing has and the frequencies will automatically will be estimated After all information is entered click ok Select which frequency mar
31. machine the autophasing will automatically correct the connections 3 Ifthe machine is a VFD machine autophasing is automatically turned off The connections must be manually corrected See Chapter 9 for assistance 4 Click Run Electrical This will run all pre programmed settings for the machine in question 5 When testing is done scan the front panel results for accuracy If all is fine write the testing to the database 1 After hookup is accomplished click on the check connections button Looking at gathered data It is important to look at the data gathered prior to writing it to the database If the data is deemed to not be good it can lead to misinterpretation of results Parameters can be adjusted and the testing redone if the front panel results are not reasonable for the machine Adjusting parameters If the torque speed curve has a red dot appearing in the graph area it can be from a speed miscalculation rotor bar problems an incoming voltage problem or another cause Check the speed in the nameplate 2 24 2010 71 005 V2 EN 117 EXP4000 Example test and report generation Torque Speed aes 11 06 7 38 3 69 3420 0 3500 0 0 3600 0 RPM Fig 10 2 Torque speed graph from main panel If the current draw Is incorrect check the CT selection from the front panel or the connections button The physical connection may not be right or there is a bad connection Other adjustments There are a fe
32. must be de energized for installation 15 WARNING Because of the dangerous currents voltages and forces encountered safety precautions must be taken for all tests Follow all corporate guidelines and those included here Due to the wide diversity of machine applications no attempt is made here to list or review all specific manifold general safety precautions However this manual includes special safety precautions applicable to the use of the EXP4000 16 NOTICE The maximum rating of the EXP4000 is 1 000 V 500 V for DC operation 1 000 V 500 V DC operation is the maximum allowable voltage between any two of the four voltages and the ground clip Under no circumstances connected the voltage sensing circuit to higher voltage levels this will cause severe damage to instrument 17 NOTICE The maximum voltage rating of the EXP4000 DC current meters is 600 V Under no circumstances connect the current sensors to circuits of any higher voltage this will cause sever damage to instrument Installation safety warnings Baker Instrument Company an SKF Group Company recommends the following safety precautions 7 Comply with all your facility s safety practices at all times 8 Ensure physical setup does not interfere with your facility s current or intended operation Additionally these safety precautions must be followed otherwise dangerous shock hazards may exist 37 Use whatever safety equipment required by your organ
33. not submerge in water or other cleaners or solvents To clean the screen take a soft water dampened cloth and gently wipe the surface Installation requirements The unit may be operated 1 Flat on the its bottom with lid open There are no ventilation requirements The unit is intended for use in Installation Category II Portable Equipment Measurement Category Ill areas and pollution Degree Environments where occasional non conducting condensing pollution can be encountered Pollution degree II From IEC 61010 1 3 6 6 2 Only non conductive pollution occurs However temporary conductivity caused by condensation is expected Power requirements Using the provided AC power cord connect the unit to a grounded AC power source The unit s power requirements are 100 240 V AC 50 60 Hz 3 A AC maximum current draw Environment conditions storage The unit is for indoor use If used outdoors the unit must be protected from rain snow and other contaminants Store instrument inside in order to avoid water contamination The unit has been tested for use up to 2 000 m altitude The tester should only be operated in temperatures ranging from 41 to 104 degrees Fahrenheit 5 C to 40 C This unit is for use at a maximum relative humidity of 80 for temperatures up to 31 C decreasing linearly to 50 relative humidity at 40 C Unpacking the unit Carefully remove the following items from the shipping boxes EXP40
34. of the machine may warrant moving the threshold level to a higher or lower value For example additional cooling of the machine may be a reason for allowing a higher load level prior to issuing an alarm Qptions Help Fi Machine Perf NP Speed 1725 Volts 230 HP 10 50 Amps 12 10 i Load p Results Test Log Thresholds Measurement 150 00 And Up Load 70 3 Speed RPM fi 751 9 Eff Srv Factor 0 70 NEMA Derating fi 00 1 Fig 1 7 Load test within the machine performance domain Operating Condition Each induction motor has a torque speed and current speed characteristic operation curve These curves will vary their signature if an induction motor s operation changes from healthy to a faulted condition For example increased operation temperature fluctuating environmental conditions varied power supply conditions or broken rotor cages can alter a motor s operating condition Differences in operating condition could indicate two things 1 A change in the operating process 2 A condition that may influence the motor s operation A resultant warning does not necessarily imply a defect in the machine load or power supply However it is important to monitor the machine s operating condition Any identifiable changes could affect the future operation of the motor oe Options iip ES NP fp Vota 230 Pi Me a Operating Condition Feni Test Log 1 Measurement Thresholds
35. or Folder View these functions include creating a New Database Folder or DC Machine Also included are the database functions of Open or Close databases and Compact and Repair This function keep the data in good operational order and helps the user repair the database if file corruption has occurred This mechanism is for Access database structure only and is equivalent to defrag on a hard drive There are also Delete folders or machines Rename the items change the style of the view screen to Grouped from Standard which is used for viewing on some computer screens The Open File Location is operated from the database level only and opens a window showing where the file is located on the drive Finally Properties for the Database and Folder level offer a brief bit of information on what the database or folder is named and when it was last modified Properties at the machine level are much more intensive and show all information that was entered via nameplate machine application manufacturer online testing and bearings Some items within these tabs can be edited x Location Nameplate Machine Application Manufacturer Online Testing Bearings Name LINE 12 Modified Date Modified Time 2 01 59 PM Fig 8 13 Right click menu properties 2 24 2010 71 005 V2 EN 80 EXP4000 DC software overview Online testing menu In order to begin testing tasks must be completed to have an understanding of what Is being
36. or over speed damage to the motor The field s resistance varies too much from the drive s motor model which may Introduce stability problems to speed or torque control On Inexpensive motors with no speed control the motor can overspeed possibly causing damage Field lead lengths cause additional voltage drop prior to reaching field winding terminals Many drives have motor models used to offer higher quality speed torque controls The field s resistance varying too much from the drive s motor model may introduce stability problems to speed or torque control Possible problem root cause Case ll If gt If_ base Drive setup problem Drive or sensor malfunction Short in field Possible Effects Many drives have motor models used to offer higher quality speed torque controls The field s resistance varying too much from the drive s motor model may introduce stability problems to speed or torque control 2 24 2010 71 005 V2 EN 89 EXP4000 DC software overview Results Vf lt Vf_field_weakening Possible problem root cause Case If lt If_field_weakening Drive setup problem Drive or sensor malfunction Possible Effects Over speed trip Over speed damage Series poles connected in series have been removed from the circuit Possible problem root cause Case ll If gt If field weakening Field circuit s resistance is lower than nameplate suggests
37. or view the connections As in the other items it is directly linked to basic software for the EXP4000 File Machine Tools view Options Help IOI Scope Ctrl 5 Oe Connections Fig 6 4 Tools menu View Menu For convenience there has been a number of preset features developed to evaluate data These views can be used as Is or the user can customize the screen through the right click menu File Machine Tools view Options Help rI Change View gt Play Back I Y Volt Currents vA RMS V Voltages 200 4 00 6 00 8 00 Currents 0 00 10 00 Power Factor Power Apparent Power Reactive Power Z Angles Machine 0 00 New Fig 6 5 View menu 2 24 2010 71 005 V2 EN 64 EXP4000 Continuous monitoring software overview View menu label Volts currents Root mean square of the currents through phases A B amp C This number should be between 30 and 110 of nameplate current Voltages This displays the root mean square of the voltages for A B and C in volts Currents The displays the root mean square of the current through the phases A B and C CT s in amperes along with the average of the root mean square values of the 3 phases currents in amperes Power factor This displays the power factor phases of A B amp C and the Average Power Factor for the phases These values are always equal to or Smaller than one and increase with the load Power in kilo watts Displays single phase complex
38. precautions must be taken to avoid injury to personnel and damage to property 7 Warning Because of the dangerous currents voltages and forces encountered safety precautions must be taken for all tests Follow all corporate guidelines and those included here Due to the wide diversity of machine applications no attempt is made here to list or review all specific manifold general safety precautions However this manual includes special safety precautions applicable to the use of the EXP4000 8 NOTICE The maximum rating of the EXP4000 is 1 000 V 500 V for DC operation 1 000 V 500 V DC operation is the maximum allowable voltage between any two of the four voltages and the ground clip Under no circumstances connected the voltage sensing circuit to higher voltage levels this will cause severe damage to Instrument 9 NOTICE The maximum voltage rating of the EXP4000 DC current meters is 600 V Under no circumstances connect the current sensors to circuits of any higher voltage this will cause sever damage to instrument Operational safety warnings Baker Instrument Company an SKF Group Company recommends the following safety precautions 3 Comply with all your facility s safety practices at all times 4 Make sure physical setup does not interfere with your facility s current or intended operation Additionally these safety precautions must be followed otherwise dangerous shock hazards may exist 13 Use whatever safety e
39. the ratios of the PTs and CTs whenever a motor is tested at the low voltage side of PTs and CTs Machine information The only required element in the machine information section is the Machine Name This will automatically filled from the Name Plate section The location and building will be filled in from the default database items All other information is optional however it can be important for tracking instrumentation and report generation Create Machine AY voto Desion Enesay information Serial Number Manubactor location building Basement Alamo Do not close after creating machine Fig 3 10 Create machine Machine information Motor design Energy information Create Machine Mane Plate Machine Infamati n Motor Design Energy Information eae ene Locked Rotor 0 00 Service Factor 1 00 Insulation Lead Res Ohms EP Serial Number Enclosure a Do not close after creating machine Create Machine ii Hours per day 0 00 Do not close after creating machine Fig 3 11 Create Machine Motor Design Energy Information sections The information entered into the motor design and energy information sections of the create machine section are optional items except for Service Factor which will be 2 24 2010 71 005 V2 EN 40 EXP4000 Basic software overview automatically calculated from previous input information Remember the more Information that is entered the more accurate results
40. voltage unbalance Armature circuit s inductance too small Possible Effect The drive s supply introduces excessive variations in the motors armature current This creates excessive torque ripple for applications defined as essentially torque ripple free Some applications for example extruders do only function properly if the supplied torque is sufficiently constant AC current components contribute more to heating than to torque generation aging the armatures prematurely Additionally AC armature current components diminish the commutation capacity 2 24 2010 71 005 V2 EN T2 EXP4000 DC software overview Machine The Machine domain displays the issues directly related to the motor s health A machine can be a motor or a generator 1 Click on the machine domain button 2 Click on any of the machine domain tests to view the test results or logs available Fig 8 34 Machine domain Armature current level Function la level represents the current flowing through the armature winding Arm Current Level ES arm Current Level 2 01 x Results Test Log Results TestLog Measurement Thresholds oS la Level 2 110 00 And Up 105 00 110 00 0 0 105 00 81 3 Nameplate Arm Current lada 330 07 Torque Pros la Level Caution Warning 81 30 105 00 110 00 Load 62 33 If 2 123 67 Date Time Print Close Fig 3 35 Armature current level Typical
41. will be Edit machine The Edit Machine menu items allow changes to any new Machine ID s information The same screen views are available as for creating a machine Edit any item that were entered incorrectly or incompletely Note In order to avoid the creation of erroneous data in the baseline the EXP4000 does not allow changing some nameplate data fields after data has been taken and stored In order to edit these fields it is necessary to create a new machine ID The data previously taken cannot be moved to the new machine D so testing will have to be repeated 1 Locate the machine that needs to be edited within the Machine Tree 2 Click on the Edit Machine function in the Machine menu The Edit machine dialog boxes will appear It will show the information 3 Edit the appropriate fields and click Apply Delete a machine 1 Click the machine tree function under Machine menu 2 Scroll through the list of machines and find the correct machine to be deleted 3 Highlight the machine and hit delete on the keyboard 4 A caution box will appear to verify if the deletion is correct Note this action permanently deletes the machine and all associated tests It cannot be undone so verify that this action is correct prior to deleting Acquire EP serial number The Acquire EP Serial Number permits association of a particular EP with a Motor ID This will enable the direct storing of data taken via an EP without the need of selec
42. with appropriate data for the EXP4000 software Fields marked in yellow can affect the results the EXP4000 can generate Remember the more information that is accurately entered the more applicable the results will be The software will prompt for missed information The EXP4000 software also includes IntelliCreate technology that checks the applicability of entered data IntelliCreate identifies the majority of typos and omissions of data fields during machine creation Name plate Create Machine E o0 Amps 1000 O Frequency gjsoo a Do not close after creating Craie Machine Cancel machine Fig 3 8 Create machine name plate tab Machine Name HP Volts RPM KW and AMPS are required data on this tab Appropriate KW data will be automatically entered to match the machine 1 Click in Machine Name and give the motor an appropriate name per the process that it is running 2 Tab between the other views 3 Notice that some items will automatically calculate and apply the appropriate value Sensor ratio When connecting to the secondaries of CT s and PT s in the field the sensors ratios xi pp E t Sensor Ratios kod Vlachine Neme XI HP Volts D E e RPM 0 B Do not close after creating machine Cancel Fig 3 9 Create machine Sensor ratios 2 24 2010 71 005 V2 EN a7 EXP4000 Basic software overview button opens a Sub panel from the Name Plate Tab Note This needs to be set up with
43. 0 71 005 V2 EN J5 EXP4000 DC software overview Typical thresholds Warning threshold 120 rated lt If Caution threshold 100 rated lt If lt 120 rated DC machine If troubleshooting Result Field current level is too high Possible problem root cause VF too high Field circuit resistance too low or cold field windings Short in field windings Possible effects Too many IR losses Result Field current level is too low Possible problem root cause High temperature High contact resistance Long leads of small diameter copper Possible effects Over speed Stalling _ Load Load 5 x The load domain uses the motor as a sensor to look at the driven load To fully describe the steady state behavior two components are supplied Torque ripple Imaged data short term behavior as well as load signature Load level history long term behavior is made viewable Close Fig 8 39 Load domain 1 Click on the Load domain to view tests 2 Click one either of the domain tests buttons to view the test results or logs avallable 2 24 2010 71 005 V2 EN 96 EXP4000 DC software overview Torque ripple Torque ripple is defined as the division of maximal torque divided by average torque during the acquisition period Powe E 1700 i 0 Fig 8 40 Torque ripple Function Torque ripple is a measure of how small the torque band
44. 0 foot pounds per second or 745 7 watts Kilowatt A unit of power equal to 1000 Watts Load What the motor drives MCC Motor Control Cabinet Motor ID Unique name tot he motor to be tested NEMA Derating Factor Factor between 1 and 0 Displays how much a motor has to be derated according to NEMA to accommodate for sub optimal voltage conditions NEMA Unbalance Number commonly defined in percent according to an algorithm specified by NEMA Displays how much of relative unbalance is part of the voltage condition Newton Meters Metric unit of torque Overcurrent Measure of operating current in percent comparing to the motors nameplate Phasors A vector that represents a sinusoidal varying quantity as a current or voltage by means of a line rotating about a point in a plane the magnitude of the quantity being proportional to the length of the line and the phase of the quantity being equal to the angle between the line and a reference line Pound Feet English system Power Factor Relative amount of operating current and voltage used to transmit power It is defined as the division of real power by the multiplication of current and voltage Service Factor Specified on the nameplate displays the amount with which the rating of the motor may be multiplied for transient operation Test Domains The five testing regions within the EXP4000 2 24 2010 71 005 V2 EN 140 EXP4000 References Thresholds The point at w
45. 00 Power Cord 2 24 2010 71 005 V2 EN 15 EXP4000 Safety equipment warnings and CE compliance statements CTs PTs Cabling Operator s Manual Shipment The EXP4000 is shipped in factory foam filled containers Should the tester need to be returned to Baker Instrument Company an SKF Group Company we recommend using the unit s original packaging or any equivalent casing that meets the following specifications Corrugated cardboard package containers double walled with a minimum burst test of 275 pounds per square inch and Two to three inches of shock absorbent material surrounding the entire unit Note Cardboard newspapers and similar materials are not considered good shock absorbers 2 24 2010 71 005 V2 EN 16 EXP4000 1 EXP4000 tests Test domains testing theory The EXP4000 utilizes a multitude of tests to determine the power condition health load and energy profile of machines The following test domains describe the functionality of the instrument along with a description of each test Testing Capabilities The EXP4000 is equipped with standard software to Initiate testing Additional software can be purchased if necessary to complete the program the user deems necessary This additional software is explained in chapters later in this manual The standard software includes the following domains and tests Power Quality Voltage Level Voltage Unbalance Harmonic Distortion
46. 000 Medium or high voltage Db25 gt scl gt PT and CT low voltage circuit in MCC a gt Connection of EP1000 138 2 24 2010 71 005 V2 EN EXP4000 Appendix E References List of References Standards 1 a b c d e f g h Ul k y m NEMA Std MG 1 2003 Motors and Generators Literature Mohan Underland Robbins Power Electronics Wiley amp Sons 1989 second edition ISBN 0 471 58408 8 El Hawary Electrical Power Systems Reston Publishing Company 1983 ISBN 0 8359 1627 4 Gross Power System Analysis John Wiley amp Sons 1979 ISBN 0 471 01899 6 Stevenson Elements of Power System Analysis 1982 fourth edition ISBN 0 07 061278 1 Fink Beaty Standard Handbook for Electrical Engineers McGraw Hill 2000 fourteenth edition ISBN 0 07 022005 0 Dorf The Electrical Engineering Handbook CRC Press 1993 ISBN O 8493 0185 8 Fitzgerald Kingsley Electrical Machinery The Dynamics and Statics of Electromechanical Energy Conversion McGraw Hill 1961 New York Toronto London second edition Wiedenbrug Measurement Analysis and Efficiency Estimation of Three Phase Induction Machines Using Instantaneous Electrical Quantities Dissertation submitted to Oregon State University September 24 1998 Buscarello Practical Solutions to Machinery and Maintenance Vibration Problems Revised Edition Update International Inc 1997 O Flynn Moriarty
47. 005 V2 EN EXP4000 122 Appendix A Default settings Database Directory InstallDirNdB Archive Directory InstallDir Archives EP Acquisition Find Machine Associated with EP Auto Assign it Elec Acquisition Options 10 Sec Note 2 Pole Machines are always acquired with at least 30 seconds despite this setting Default settings Teto Yellow Red Electrical Voltage Level Overvoltage Pp nde Voltage 5 10 Pp balance KH Pp Distortion HT Rotor Condition BB Operating Condition KOH er O O O pf ver Current aoo aa O Efficiency PaybackPeriod 24Mo 12M Spectrum Acquisition 3000 FMax 1 37 Acq Time Vibration Vibration in sec Operating Condition 10K 20 Machine Tree TreeLevel1Name location pi Tree Level Names Building Units USCustomay Currency Dollars Voltage LinetoGround OOOO Machine Tree Show Machines with No Tests Filters Show TestswithaGoodrating Show Tests with a Caution rating O O o IO y Warning rating C T ci MO PU Date 2 24 2010 71 005 V2 EN 123 EXP4000 Default settings 2 24 2010 71 005 V2 EN 124 EXP4000 General Appendix B Troubleshooting Connection troubleshooting The EXP4000 has 2 different modes of operation Non VFD 60Hz or 50Hz line operated or VFD Variable Frequency Drive mode The requirements for either of these modes are slightly different from a connection st
48. 2 Stator resistance estimator Motor Master Used in USA only Requires additional software Allows the identification of inefficiently operating motors Can calculate wasted energy and money savings Assesses pay back periods for replacing motors with more energy efficient equipment ti Matormaster for Goneral Distribution Inc Fi ld date Lit Compara Savings iracka Options Melo ees wl Fig 3 23 Voltage and Current vs Time IEC efficiencies The IEC efficiencies option shows European Eff from the IEC standard table This shows the different efficiency classes as a function of the motor s rating and full load efficiency The second tab the D O E table shows the minimal nominal efficiency for motors in accordance to EPAct 92 and 1 2 24 2010 71 005 V2 EN 47 EXP4000 Basic software overview Fig 3 24 IEC Europe and IEC DOE efficiency tables Options menu items Options Help Test Notes Override Speed Electrical Acquistion Options Spectrum Acquisition Options EP Acquistion Options Dag Card Settings Display Fig 3 25 Options menu Test notes The test notes command allows creation of memos and Identifies who tested the motor ID 2 24 2010 71 005 V2 EN 48 EXP4000 Basic software overview i Test Motes Tested For Memo OF Cancel Fig 3 26 Test Notes Override speed The override speed function is used to manually ente
49. AN Established 1981 Advanced Test Equipment Rentals www atecorp com 800 404 ATEC 2832 User s Manual EXP4000 Baker Instrument Company an SKF Group Company 4812 McMurry Ave Suite 100 Fort Collins CO 80525 970 282 1200 970 282 1010 FAX 800 752 8272 USA Only Note This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference with the equipment is operated in its installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the product manual may cause harmful interference to radio communications If this equipment does cause harmful interference the user will be required to correct the interference Due to the phenomena being observed and the material properties being measured this equipment does radiate radio frequency energy while in the active test mode Care should be taken to Insure this radio frequency energy causes no harm to individuals or other nearby equipment Information furnished in this manual by Baker Instrument Company an SKF Group Company is believed to be accurate and reliable However Baker Instrument Company an SKF Group Company assumes no responsibility for the use of such information or for any infringements of patents or other rights of third parties that may r
50. FD analysis software The use of variable frequency drives VFD s are widespread These types of rotating machinery are highly useful however are difficult to analyze for problems due to their variable nature Operation details The VFD Details window can only be activated if the measurements were taken in VFD mode This window displays the dynamic behavior of voltage level torque frequency and speed as a function of time VFD mode The EXP4000 has 2 different modes of operation VFD and non VFD 60Hz or 50Hz line operated For these two modes the connection requirements are slightly different In VFD mode the Autophasing feature is off Correct phasing of CT s with respect to voltage leads needs to be ensured by the operator Each CT must be connected to the correct phase and with the correct polarity In other words if two or three CT s are connected to the wrong phases the results displayed by the EXP4000 will not be correct Or if one two or three of the CT s are hooked up with the wrong polarity arrow pointing in the wrong direction then the results cannot be correct The following table displays issues and their corresponding solutions Note If in VFD mode the Voltage Level is only displayed as a function of time This mode of operation is not a pass caution warning mode any longer All voltage level tests performed in VFD mode will lead to a blue color Issue Possible Cause Note that V Voltage is connected in Swap
51. Field Voltage Armature Current l Field Current l Field Armature Fig 8 1 Basic diagram separated excited DC motor Connection cases Current sensor connections I lt 600A l 100A Standard DC portable sensors Standard DC3000 current sensors have two ranges 60 A 600A Il 10A 100A II 600 A lt l lt 15 000 A or gt 100A Optional DC portable sensors NOTICE The maximum voltage rating of the EXP DC current meters are up to 600 V Under no circumstance connect the current sensors to circuits of any higher voltage This will cause severe damage to the EXP4000 Optional DC current sensors are available extending the current range above 600 A for the armature and or above 100 A for the field Field Armature Portable Armature Fig 8 2 Connection diagram portable 2 24 2010 71 005 V2 EN 76 EXP4000 DC software overview Voltage sensor connections V lt 500 V The EXP voltage connection is made directly across the armature voltage or field voltage Fig 8 3 shows the field voltage connections Field Portable Field Voltage Connection Fig 8 3 Portable field voltage connection less than or equal to 500 V V gt 500 V If the DC motors voltage exceeds 500 V then a resistive bridge can be used to supply a lower proportional voltage to the EXP4000 Fig 8 4 shows this done for the field voltage circuit Portable Field Voltage Connection Fig 8 4 Portable fiel
52. Fig 9 5 the blue CT is disconnected and an electrical test is performed Notice the amplitude is zero However if the CT is not totally closed then phasor will be greater than zero but noticeably less than the other CT s AN Connection Setup Physical Connections af se ca OFF CALC OFF OFF la Rome ae ay Volts Angle Amps la 1 7 joo vafizze foo IB 0 0 317 6 vB 133 8 120 0 IC rs 290 0 vc 134 8 Abort Test Continue Test Fig 9 5 2 CT physical connection In Fig 9 6 there are several problems with the phasor setup Notice the warnings Red CT may be connected improperly and yellow CT may be connected improperly In the above position la is roughly where Ib should be and the yellow phasor is roughly where the red phasor should be Please note that although the blue CT was the one disconnected the yellow CT is the one that needs to be calculated This is because within the physical setup the red CT was connected where the yellow CT should have been the yellow CT was connected where the blue CT should have been and the blue CT was disconnected The Suggest button will be helpful in sorting through setup problems My Connection Setup x Phasors Physical Connections a OFF p CALC OFF p CALCOFF CALC Reset Amps Anal Volts Angle l 17 50 0 VA 1328 foo IB fie 164 5 VB 133 8 120 0 IC ra 290 0 ve 134 8 240 0 Abort Test Continue Test Fig 9 6 Phasor Connection Manually
53. HINE A E NOM Ar 64 e saad tte E E conan 64 ON 64 OPUS AA AI AS ALAS AN NDA 66 SAP OU IM ar 66 A O EO 66 General opora ON ICONS dadas 6 Modifying continuous monitoring tool ia A A RAS 6 AUN EVA Oran stesso o 6 Editing ganges and Grapho caca ananasa a wie aces aaa Tasos Sexton du acc vaute easiness sont cans bat deems 68 CMAN CVE SCT COM asia sated axoeeete S E dacs stan EA O A T ATARE 70 7 ENAN PANAON AEE AE EE TEO A E E O T E T A E T E O 71 Vibration software Overview crac A Are 71 Vior raton Mode sic a aa a a a 71 vIBration ces MOE Sa A E A 1 TO assidhra VIDFAUOM tester ita 1 create vibradon testeo A a 1 To edt a Drato tE SN ad 72 To delete Vibration testimonio 12 llarg oi o A eas dean tas aia dace A O E tea taaeins 73 ci 75 DC SoftWare Over WeWiossia aid A 75 OC macnine Dynamic analysis EA a eae akon PS DESUNmMan OP tests Ge Teal OS aa Na 5 Types of problems identified with DC3000 occoccncccccccacananoninonccinacanananonnonaconaconnona nana cnnccnnaranonnnos ES DC connections tor the EAP 4000 portable SENSO ari ion 75 DC SEM SOR VOJETA UNO rE O N T NAN Ves CONNECT Si a a AA 76 voltage Sensor COMMECUONIS bi apiascabadsteelesietemictaaneasbasauuveumeaalecectppa A 71 DC3000 software navigation and Overview sesssssessessessesesresessessesresrsresresresesrestesresesresreseeresresreese 71 A A AR 78 2 24 2010 71 005 V2 EN 9 EXP4000 Table of Contents Onenna a database diosa 78 Geis em als C Vrs ols are eenee e
54. LASSIC PROBLEMS E BAD_ROTOR_BAR H a CT_BAD_ROTORBAR H Fa INCIPIENT_ROTOR_BAR C Aa LOW_EFFIENCY m a MILD_ROTOR_BAR OVER_CURRENT a 4 7 17 2001 9 41 46 AM 4 7 17 2001 9 40 34 AM o 4 7 17 2001 9 38 42 AM C a OVER_CURRENT_ESF H Ya ROTOR_BAR et VFD_VOLTAGE_DIST H O VOLTAGE_LEVEL C Ma VOLTAGE UNBALANCE Fig 3 3 Reports selection A rtf file is generated by the EXP4000 that can be opened in Microsoft Word WordPad and several other word processing programs for editing Remember that report page count will increase dramatically with the addition of multiple tests This can increase time in report generation and printing Exit The Exit menu item closes the program Machine menu items The Motor Menu allows the user to assign create edit or delete particular motors to be tested Under the Motor Menu are the following options machine tree create machine edit machine acquire EP serial number and reset EP serial number Machine Thresholds Tools Op Machine Tree Fz Create Machine F3 Edit Machine Acquire EP Serial Number Reset EP Serial Number Fig 3 4 Machine menu 2 24 2010 71 005 V2 EN e EXP4000 Basic software overview Machine tree The Machine Tree allows the user to quickly open databases perform tests on motors within a database and view different filters to access specific test information quickly and easily The database menu allows the user to create a new open
55. SCLAIMER OF DAMAGES SHALL APPLY TO ALL CLAIMS MADE BY LICENSEE RELATED TO OR ARISING OUT OF LICENSEE S USE OF THE SOFTWARE INCLUDING BUT NOT LIMITED TO CLAIMS ALLEGING THAT THE SOFTWARE OR ANY COMPONENT THEREOF FAILED OF ITS ESSENTIAL PURPOSE OR FAILED IN SOME OTHER RESPECT b Acknowledgment The User agrees that the limitations of liability and disclaimers of warranty set forth in this Software License will apply regardless of whether Baker SKF has tendered delivery of the Software or the User has accepted the Software The User acknowledges that Baker SKF has set its prices and granted the licenses contemplated herein in reliance on the disclaimers of warranty and the limitations and exclusions of liability set forth in this Software License and that the same form an essential basis of the bargain between the Parties 7 Term and Termination a Term The licenses granted herein shall commence on the User s acceptance of the terms of this Software License and shall continue in existence until it is terminated in accordance with Section 7 b below b Termination Baker SKF may terminate this Software License and the license conveyed hereunder in the event that the User breaches any provision term condition or limitation set forth in this Software License including but not limited to the license restrictions set forth in Section 2 b of this Software License c Effect of Termination Within ten 10 days after termina
56. Thresholds menu items Vibration Test Models To assign a vibration test model Fig 2 Assign vibration test model 1 Click on the Thresholds menu Click on the Assign Test Model menu option 2 Click on the drop down box below Select Test Model Both electrical and vibration test models will be listed here 3 Highlight the appropriate one for the operation needed 4 Click on Assign to assign the option Create vibration test model Click on the Thresholds menu Click on the Create Vib Test Model menu item 1 Assign a name for the test model 2 24 2010 71 005 V2 EN 1 EXP4000 Vibration software overview Vibration VIBRATION VELOCITY IN SEC PEAK Caution Level 0 15 WamingLevel BB Operating Condition PATTERN DIFFERENCE Caution Level 20 00 Waming Level 30 00 OK Cancel Fig 7 3 Create vibration test model 2 For the vibration velocity test determine the caution level and warning level thresholds in sec peak Adjust thresholds by clicking the up and down arrows or by entering numbers in the text field 3 Pattern Difference 4 Click Save The computer will prompt the user to confirm that the desire to create a new electrical test model Click Yes 5 Click Close To edit a vibration test model 1 Click on the Thresholds menu Click or press on the Edit Test Model menu item 2 Click or press on the arrow to the right of the Select Test Model text field Select the desired te
57. _ESF le 4 PEREA eC 4 5 20 2001 10 38 08 AM LEJA 9 20 2001 10 37 31 AM H O Ya ROTOR_BAR m VFD_VOLTAGE_DIST H O Ha VOLTAGE LEVEL H O MA VOLTAGE _UNBALANCE E oe Fig 10 8 Report generator o Using the Filter sub menu filter the displayed results by result status or by a specific data range Show Good Results Show Caution Results Show Warning Results Date R ms Date Range BAR 1 62 17 Ya INCIPIENT_ROTOR_BAR 6 0 Ma LOW EFFIENCY Fig 10 9 Reports filter on Click the Select toolbar to select all of the displayed results for reporting o Using the Select sub menu automatically select results based on result status Click the trending on button to view trending parameters By clicking on the word Trending On it will change to Trending Off Trending On All Good All Caution All Warning All Warning and Caution DF EAR JM OVER_CURRENT Fig 10 10 Reports select 2 24 2010 71 005 V2 EN 120 EXP4000 Example test and report generation Click on Ok after all parameters for the report have been developed The report wizard will now create the report the user can save it as a rtf type file It can then be reviewed In an assortment of software Trending On All Machine Results Selected Results Only T BAD _ROTORBAR 1 Fig 10 11 Reports trending on Viewing annotating and printing reports After the report has been generated via the wizard the rep
58. achine edit machine 2 Enter a new name into the machine name field Click apply A screen will popup saying Machine Name has changed Create a New Machine Select no to update the existing machine 3 Click either yes 4 All nameplate fields will now become editable Make changes as appropriate and click Apply This will create a new machine without any test data 5 In order to view this new machine click on Machine and then Machine Tree 6 Click on View and then Reload This will load the new named machine into the tree 7 Click on the machine and perform tests again Note An existing machine with recorded tests cannot be edited In order to edit this machine the use must delete all tests and then edit the machine How do connect the EXP4000 to the secondaries of PT s if have an open delta configuration Open Delta configurations are the most common case in the field for medium or high voltage motors 1 Ensure all safety precautions are being followed when working with live voltage See Preface for safety precautions 2 Identify the three different points in the MCC that show the same voltage typically 100V 200V when connecting A B B C C A One of these pins typically is the ground pin 3 Clip the ground connection to a viable ground in the MCC Note that commonly this will be one of the three pins that was previously identified 4 Connect the three phase clipons to each one of the pins that was ident
59. aired Safety term definition DANGER Indicates a hazardous situation which if not avoided will result in death or Serious Injury WARNING Indicates a hazardous situation which if not avoided could result in death or Serious Injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE This signal word addresses practices that could result in property damage but not personal injury Symbols Labels on equipment A Caution Indicates a hazardous situation which if not avoided could result in personnel injury and or equipment damage AN Voltage level warning Located on labeling for test leads on right side of instrument 2 24 2010 71 005 V2 EN 105 EXP4000 Physical connections of EXP3000 Connection setup wizard Current Input Use specified current probes EP Vibration Input Use specified EP and Vibration cables Voltage Input A AC 1000 V CAT III AN DC 500 V Fig Pre 1 Safety Labels from EXP4000 Other Important Safety Warnings 5 Warning When the instrument exterior case is open the instrument is not water resistant Do not allow the opened instrument to be exposed to water Water in contact with the interior of the instrument compromises protection features and could result in serious injury or death 6 Warning Because of the voltages present the test should be conducted only by trained personnel and adequate safety
60. al injury Symbols Labels on equipment Caution Indicates a hazardous situation which if not avoided could result in personnel injury and or equipment damage Voltage level warning Located on labeling for test leads on right side of instrument Current Input Use specified current probes EP Vibration Input Use specified EP and Vibration cables Voltage Input A AC 1000 V CAT III AN DC 500 V Fig Pre 1 Safety Labels from EXP4000 2 24 2010 71 005 V2 EN 13 EXP4000 Safety equipment warnings and CE compliance statements Other Important Safety Warnings 1 Warning When the instrument exterior case is open the instrument is not water resistant Do not allow the opened instrument to be exposed to water Water in contact with the interior of the instrument compromises protection features and could result in serious injury or death Warning Because of the voltages present testing should be conducted only by trained personnel and adequate safety precautions must be followed to minimize the risk of serious Injury death or property damage Warning Because of the dangerous currents voltages and forces encountered when operating testing or repairing rotating equipment safety precautions must be taken for all tests Follow all safety precautions in this manual and required by your employer Due to the wide diversity of machine applications it is impossible to list all general safety precautions Howe
61. andpoint of view For VFD connection troubleshooting please see Chapter 5 Non VFD mode This mode is operated in two different ways with or without autophasing Autophasing allows for automatic correction for proper phasing of the current transformers CT s with respect to the connected voltage phases The autophasing feature is designed to recognize which CT s signal belongs with which polarity and to which connected voltage signal It requires that the observed three phase load be only an induction motor without power factor correction downstream of the point of connection lf any other device is being observed the autophasing feature needs to be turned off w l eee Monitored speed is wrong Motor is running at high load yet EXP4000 is displaying low load Motor is running at no load yet EXP4000 is displaying a high load The device connected is either not a 3 phase induction motor or there are power factor correcting capacitors down the line from the point of connection Autophasing failed Rare Autophasing failed Rare 2 24 2010 71 005 V2 EN EXP4000 Turn the autophase feature off and be aware that portions of the data incl speed torque rotor bar efficiency are compromised Turn autophasing feature off ensure proper phasing in connection save data and send to Baker Instrument Company an SKF Group Company for further tuning of autophasing feature Turn autophasing feature off ensure pr
62. ark the four mounting holes 5 Remove the plug and drill the four outer mounting holes 6 Mount the plug and the backplate using the supplied hardware 7 Provide strain relief for the cabling attached to the panel plug x Current Transformer CT Connections 1 Verify that all three CTs are marked with the same bin number this is a number between 1 and 5 2 The supplied CT donuts are to be placed on the three voltage feeds to the motor 3 These should be placed on the load side of any line protection devices circuit breakers Care should be taken to ensure the dots on the CTs point toward the load motor Red is phase A blue is phase B and yellow is phase C 4 The Baker CTs should be installed on the output of existing CTs in the system for all motors operated at voltages above 1 000 V Check that the output of the secondary Is less than or equal to the rating of the Baker CTs 5 Ensure there is enough wire length to connect to the EP If installed CTs are used be sure to note the ratio as this information will be needed when creating a motor ID 2 24 2010 71 005 V2 EN 133 EXP4000 EP1000 installation Voltage Connections NOTE On motors with input voltages higher than 1 000 VAC it will be necessary to make the connection after a Power Transformer PT located between the voltage source and the EP Three phase voltage should be connected to the EP once it is installed Installing a fuse block near the EP conn
63. ase click File and then Close Database This will close the database Creating a new folder Too create a New Folder click File and then New Folder The new folder will locate itself in the Tree View 4 DC Machines a bine Ae Fig 8 8 New folder 2 24 2010 71 005 V2 EN 78 EXP4000 DC software overview Renaming a new folder To rename a new folder right click on the new folder and then on Rename in the drop down box and it will place a box around the new folder Type in the appropriate name and press enter or click outside of the folder fe Inland Direct i gt DC Machines E DART CONTAINER El DC Machines po LINE 12 Fig 8 9 Rename folder Create a new test item 1 To create a new test item click File and then New Test Item A wizard will appear to help create a new machine 2 Type in the appropriate machine name and click DC machine Click Next Create Test Item Wizard Name Create Machine __ _ Test ltem to Create Dc Machine Fig 8 10 Create test item wizard Adding an DC machine xl 3 DC machine There are a number of fields that have drop down boxes The following list are required fields x Nameplate Please enfer fhe information from fhe nameplate of fhe machine HP fo 00 kw bo Base Speed RPM jo MaxSpeed RPM fo o Field Volts gt Armature Volts A Field Amps po 0Ct lt C t Armature Amps po Number of Poles iz
64. ate Machine function F amp 4 key runs the continuous looped acquisition for 10 tests F5 key operates the Run Electrical function F6 key operates the timed looped acquisition function F7 key operates the Virtual Scope F8 key displays the Phasors F9 key operates the Transient Analysis Dialog Ctrl A About Ctrl M Manual Ctrl O Open Database Ctrl N New Database Ctrl B Create Backup Shift F5 Refresh Machine Tree 2 24 2010 71 005 V2 EN 33 EXP4000 Getting Started Ctrl F5 Reload Machine Tree Software hints Popup panels require the user to immediately interact with dialogs that affect displayed data loaded or part of a test The time required to load a machine with a large number of tests has been decreased by internally connecting or threading the test logs o When the machine is loaded but the thread is not completed the message Test log is Loading appears instead of the test log s graphs o This can cause a perceived lag if the user quickly switches machines or deletes test results from motors with more than 100 stored tests o This lag time will also be noticeable if the user loads a machine with a large number of tests and then exits o At this publishing It is recommend keeping the number of tests per motor to a maximum of 2000 2 24 2010 71 005 V2 EN 34 EXP4000 3 Basic software overview Software overview This chapter will supply the u
65. can indicate an unbalance on the rectified supply A blown SCR Onla can indicate a high contact resistance Reports To generate a report select the test records desired To select multiple test records simply use the Ctrl or Shift Keys as in any Windows format Right click and select add to report The report will be created and a popup box will appear to save the report in a rtf rich text format that can be opened in a number of different software packages Electrical Results 3 22 2007 9 07 56 AM 3 22 2007 9 07 38 AM 3 22 2007 9 07 21 AM 3 22 2007 IL Add to Report m Delete Fig 8 48 Right click menu reports 2 24 2010 71 005 V2 EN EXP4000 Wa fit Ctrl F Del 101 DC software overview Explorer DC Electrical Result LINE 2 DART CONTAINER LINE 2 Machine Name Location Test Date Time Report Date Explorer SN Nameplate Data Hp Base Speed RPM Field Volts Field Amps Winding Measurements 3 22 2007 9 07 56 AM 8 15 2007 7 08 34 PM TESTERSN 250 00 1750 00 300 00 6 55 Shunt 186 50 1750 00 kW Max Speed RPM Armature Volts 500 00 Armature Amps 402 00 Insulation Class A Field Armature 331 36 658 42 mz 66 27 306 57 384 23 191 18 66 27 Status Fail Level Average Voltage 324 84 Max Voltage 693 46 Min Voltage 13 95 Rated Voltage 108 28 Average Current 6 95 Max Current 10 23 Min Current 327
66. components Slip frequency is not separated enough from fundamental Try higher acquisition settings Efficiency No entry of stator resistance No comparable motor found in database Payback Efficiency blue condition period Missing data of a least one of the following Hours per day Days per year per kWh Current Load lt 25 Imbalance 2 24 2010 71 005 V2 EN 129 EXP4000 Blue Results 2 24 2010 71 005 V2 EN 130 EXP4000 Appendix D EP1000 installation To obtain complete installation drawings and templates please contact Baker Instrument Company an SKF Group Company and ask for document number 1 028 What to do first Please verify all needed materials are in package EP1000 3CTs Terminal block cover and hardware MCC cable EP mounting hardware Template for EP enclosure mounting Tools Needed Small flathead screwdriver Pencil or felt tip pen Phillips Screwdriver Hand drill Set of Drill bits Greenlee 2 1 2 punch Materials Needed Switchboard wire SIS 14 600 V Wire lugs 14 16 AWG 8 Splice sleeves 14 16 AWG Jy wraps T amp B 7 Wire 14 600 V color green Ground Connection Control Cable 3 C 14 AWG 600 V EPR CPE Tag Book ABC T amp B Fuse Block PT 600 V 2 Amp 2 24 2010 71 005 V2 EN 131 EXP4000 EP1000 installation Safety Precautions for EP installation DANGER To prevent serious injury or death cabinet voltage
67. components to the fundamental currents and voltages of the system Bar charts display the distribution of the harmonic content on the different frequency bands for all currents and voltages i a teed 14 ELE o O O Fig 1 5 Harmonics within the power quality domain Machine performance domain Effective service factor Divides the estimated percentage load by the NEMA derating factor Identifies thermal overloading in the motor The service factor test identifies how closely the motor is operating to Its effective service factor The test predicts heat based deterioration and provides an accurate thermal assessment of the motor Options Help Machine Perf X a NP Speed 1725 Volts 230 Elec Moc P 10 50 Amps 2 10 Mibr Mor Y Effective Service Factor A E ESF Graph Results Test Log Effective Service Factor Graph 137 5 120 0 100 0 0 0 Load 0 0 40 0 20 0 0 0 1 0 0 9 0 8 0 7 0 6 NEMA Derating ESF 0 70 Load 470 25 NEMA Derating 1 00 Print Close Fig 1 6 Effective service factor within the machine performance domain 2 24 2010 71 005 V2 EN 20 EXP4000 EXP4000 Tests Load This displays the estimated load for the machine and compares it with pre programmable thresholds A 100 threshold is commonly used since operating above that level may rapidly thermally deteriorate the machine However a combination of environmental conditions and criticality
68. d possibly resulting in increased temperature and decreased commutation and efficiency A DC motor operated from rectified three phase AC should display harmonics at the following locations DC 6 12 18 etc 1 Click on the harmonics domain button to view the harmonics involved with the machine under test 2 To view the harmonics in different formats click on the tabs on the top of the screen 3 Click on the check box to view all four channels or as few as needed for each Harmonics ou E u If la Vf Va Percent of Fundamental Harmonic MYI M if M Va Mla Fig 8 46 Harmonics 100 DC software overview channel If la Vf Va 4 Click on export to view the available data formats This allows data to be displayed in several formats clipped to the clipboard exported to a file for email or sent directly to a printer Size definitions are also available The unit of measure Is pixels Result H Exporting Harmonics 4 Export MetaFile C BMP C JPG PNG C Text Data Only M Export Destination Me ClipBoard File Printer m __ Object Size Width i 000 t 313 Units Fig 8 47 Export harmonics No Specific Size Millmeters C Inches C Points Cancel Help x The presence of any other harmonic particularly the 2 indicates a lack of symmetry except for the case of a single phase rectifier Unusually large harmonics represent On Va
69. d voltage connection greater than 500 V DC3000 software navigation and overview File Archive Online Testing Offlin O New Database Ctrl N gt Open Database Ctrl O Close Database New Folder Ctrl F New Test Item Ctrl h Exit Fig 8 5 File menu 2 24 2010 71 005 V2 EN 71 EXP4000 DC software overview Creating a new database Create New Database q f TER Type of Database to Create Access Database mdb Database Name o Cancel Fig 8 6 Create new database 1 Click File and then New Database The following screen will appear Type a name for the new database that Is appropriate to the operation and click Ok 2 This database will now appear in the tree view on the navigation pane on the screen There are three types of database structures a Access Database mdb 3 Choose the database structure appropriate to the application Opening a database 1 To open a database click File and then Open Database 2 The following screen will appear Choose the appropriate database and click on Open 3 This database will be active on the software open BL Lookin E Data Hosea Pe My Recent Documents Desktop pe My Documents DART CONTAINER mdb SE My Computer 2 LY Weta File name DART CONTAINER mdb y Open eal E A ET Files of type Access Database mdb y Cancel Z Fig 8 7 Open Database Close database Too close a datab
70. de and continues forward Event triggers Event triggers are useful to monitor data for pre defined machine events When the chosen condition exists the data will be recorded for review The software will continue to record all channels until all triggers have been recorded At that point the software will stop and all events can be reviewed The software can monitor any or all of the 41 active triggers listed All channels are continuously monitored and each trigger creates a separate event even if the time Is overlapping x Eile Options Apply the following Triggers Start Condition Start Value Stop Condition li noni ott rigger sec Channel is gt Va Cc m 0 000 Channel is lt Value 0 000 Channel is lt Value T Channel is gt Value IC RMS A Channel is gt Value VA RMSIV Channel is gt Value VB RMSIV Channe is gt Val VC RMS V Channel is gt Value I Avg RMS A Channel is gt Va 0 000 Channel is lt Value 0 000 Channel is lt Value 0 000 Channel is lt Va 0 000 Channel is lt Value 0 000 Channel is lt Va 0 000 Channel is lt Value Cc M Cc M La La ke kele e e ke fe lke ta kehe V Avg RMS V Channel is gt Value Imbal Channel is gt Val ut V Imbal Channel is gt Value L C m 0 000 Channel is lt Value 0 000 Channel is lt Value Channel is lt Val 0 000 Channel is lt Value Channel is lt Value Channel is lt Va
71. dly unbalanced voltages A common rule of thumb is that voltage unbalance can be the cause of up to eight times larger current unbalances Machines will also show very large current unbalances under very light or no load conditions even when driven by a balanced voltage These no load current unbalances are common in healthy machines These current unbalances vanish rapidly when the machine is loaded Fig 1 12 Current unbalances within the current domain Spectrum Domain Rotor bar Operating condition Records the relative amplitude of the rotor bar sideband Compares the rotor cage signature to stored thresholds sols Options Help v Rotor Bar Fig 1 13 Rotor bar within the spectrum domain 2 24 2010 71 005 V2 EN 24 EXP4000 EXP4000 Tests The rotor bar test and operating condition test evaluate the overall condition of the machine Broken rotor bars cause excess heat on the machine decreasing efficiency shortening insulation life and possibly causing core damage V I Spectrum The V I Spectrum window analyzes the frequency spectra of the 3 line neutral voltage waveforms and the 3 line currents independently of each other The current spectra have shown to contain information related to the vibration spectra of the machine It Is possible to identify roller bearing faults by using the mark frequencies option in the right click menu within the EXP4000 software see Chapter 3 for more information It is also feas
72. e 29 35 36 Database Management 29 databases 29 Delete Vibr Test Model 73 Demodulated Spectrum 53 derating factor 31 E Edit Elec Test Model 43 Edit Vibr Test Model 72 Efficiency test 22 Electrical 123 140 Energy Assessment 121 Environmental 15 F File Menu 35 Freeze 44 H H position 44 Harmonic Distortion 17 18 121 141 Harmonics 17 20 25 121 140 L Load 44 121 140 2 24 2010 71 005 V2 EN EXP4000 Index Loop Acquisition 46 M MCC 14 107 108 117 140 Menus 35 Motor Performance 121 N NEMA 31 140 O Operating Condition 17 21 123 Options 48 overcurrent test 23 Override Speed 49 P Panels 31 Payback Period 17 23 123 Phase current 43 Phase to ground 43 Phase to phase 43 Power 17 19 30 36 59 65 70 121 126 139 140 Power Condition 121 Power Quality 17 Print Currents 45 Print Graph 44 Print Panel 44 Print Summary 35 36 122 Print Voltages 45 R Recall Delete 35 Report and Exit 35 rotor bar test 25 S Save 44 72 Scope 43 44 Sec Div 44 Sensors 107 Serial 37 41 Shipment 16 Spectrum Domain 24 53 145 Index T Test Notes 48 Test Results 35 Timed 46 Tools Menu items 43 Torque Domain 53 54 Torque Ripple 53 54 55 141 Total Distortion 17 18 121 Trigger 45 U Units Div 44 User Level 48 2
73. e Database Restore To close an existing database 1 Click on the file menu 2 Click on Database and select Close 2 24 2010 71 005 V2 EN 35 EXP4000 Basic software overview 3 This will automatically close the database To delete an existing database 1 Close the database 2 Click on the file menu 3 Click on Database If needed open the folder that the Database files exist in and click on the database file that is to be deleted and then click on Delete 4 A warning will appear for confirmation on the deletion of the database Make sure this action is correct lt can not be undone Note This will not delete the folder that the Database resides in In order to delete the folder right click on the folder and chose delete Print summary report This option will print an overall summary of the testing done Additional reports can be printed by clicking the check boxes at the bottom of the summary page These reports consist of Main Panel Power Condition Report Machine Condition Report Energy Machine Performance Report 4 TimeDate 12 12 2002 11 39 53 PM F EXPLORER Database tet 7 Test Model default elec L Memo Location Basement Test By pp A A Building fAlamo TetF Machine default SerialWo 200 HP fo50 Manufacturer CS Kw 0 37 RPM 725 o Wols 230 Amps 210 serv Fact 1 250 StatorRes Ll 32 00E 0 Ohms i Frame Vo A Insulation Ff Speed RPM Torque
74. e File and Zoom Info Under File there are three items Delete Test Result Output Raw Data to File and Output RMS Data to File The Zoom Info option gives directions on how to use the tool on these graphs The Print option prints either plot The Trigger source allows the choice between triggering on Voltage V or on Current I source A 2 ESO tangs ml Cr on Tm Tiras on Tes Fig 3 19 Transient analysis Torque vs time 2 24 2010 71 005 V2 EN EXP4000 Basic software overview The Trigger level field specifies at what Amps or Voltage the Triggering is to occur When clicking on any point on either the voltage or the current displays a marker depicts the point in both panels and the voltage and current data are displayed for that instant in time The same methods of control work on the second tab of the transient analysis The torque vs time window displays two different views of the instantaneous torque In red the unfiltered torque displays the highest level of dynamic behavior of the airgap torque as calculated from currents and voltages The blue line Filtered Torque shows the same but with a lower dynamic resolution The blue line can be viewed as a short time average of the red line and it describes the fundamental behavior of the torque versus time while the unfiltered red line can be viewed as the highest level of dynamic torque display Loop acquisition The option loop acqui
75. e cabinet icon Under each database are locations for each machine depicted by a factory icon There can be another factory icon beneath the location icon This divides the location by buildings plant or other user derived descriptions Under these sections are individual machines motor icon 1 Follow the tree format until the machine is found that needs to be tested Database View Options EA test Basement E 4 Alamo default Ma Motor 7 af 10 28 2004 11 37 45 AM elec af 10 28 2004 11 37 18 AM elec af 10 28 2004 11 36 51 AM elec af 10 28 2004 11 36 24 AM elec 44 10 28 2004 11 35 57 AM elec af 10 28 2004 11 35 29 AM elec af 10 28 2004 11 35 02 AM elec af 10 28 2004 11 34 35 AM elec af 10 28 2004 11 34 08 AM elec af 10 28 2004 11 33 41 AM elec af 10 28 2004 11 32 58 AM elec Ya Motor 4 af 10 28 2004 11 51 38 AM elec af 10 28 2004 11 51 11 AM elec af 10 28 2004 11 50 44 AM elec af 10 28 2004 11 50 17 AM elec af 10 28 2004 11 49 50 AM elec A imams man Fig 2 4 Machine tree navigation 2 Double click on the machine This will display all associated tests for that machine 3 Highlight the machine to be tested and connect the EXP4000 appropriately see chapter on Connecting the EXP4000 for appropriate connections and press or click the run electrical to begin gathering data 2 24 2010 71 005 V2 EN de EXP4000 Getting Started Icons Displayed within Machine Tree Database parent directory icon i Machi
76. e the panel plug to the A D Bus DB25 receptacle of the EP and secure in place with the captive screws Provide strain relief for all current and voltage wiring as well as the DB25 cabling at the EP enclosure Verification of Installation 1 Energize cabinet 2 Connect umbilical cable between Explorer and EP panel plug 3 Open the Explorer software and create a new motor id 4 Set Sensors switch to EP position 5 Press Run Electrical button Troubleshooting EP1000 Ratings Voltage Terminal 1 000 V AC CAT Ill Current Terminal Use Specified Current Transformers A D Bus Connector Use Specified Umbilical Cable Input 5V DC 105 mA Connect Only to EXP4000 or Similar 2 24 2010 71 005 V2 EN 134 EXP4000 EP1000 installation No voltage Replace EP fuses signature MCC Sensor Verify all connections between EP and Explorer Error Autophasing Verify correct voltage and current hookup Verify arrows on CT s point toward not successful load or V sequence does not match sequence EP not Follow procedure To associate an EP with a Motor ID associated with a Motor ID Voltages and or Check correct sensor ratios currents are too small 2 24 2010 71 005 V2 EN 135 EXP4000 EP1000 installation Power Bus 1 000 V Bus and Below Connection Scheme T2 Ground DB25 Motor Leads Low Voltage lt 1 000V Induction Motor Notes 1 For medium and high voltage motors Voltage Inputs
77. ear systems transform analysis and communication theory j l Fig 4 2 Demodulation zoom in The Frequency scale at the bottom of the 3D graph has the same meaning as the scale to the bottom of the projection Typically frequency components of interest are read on these scales The Channel selector position runs the demodulation algorithm for voltage or current of the phases A B or C or over the default torque setting The graph amplitude is displayed in volts amps or Newton meters The Frequency Range setting allows for zooming in or out The scale Band identifies the different AM demodulation bands that have been analyzed via the DFLL The Viewing Controls allows changing of the settings on the 3D graphs Disabling the Projection Only view and enabling the Zoom Rotate options allows changes to viewing of the 3D graph The particular keys for zooming panning and restoring are described in the zoom info bar located in the result panels Torque domain Two tests are available within the torque domain Torque ripple and torque spectrum 2 24 2010 71 005 V2 EN 54 EXP4000 Torque software overview Torque ripple Torque Ripple Zoom Info Fig 4 3 Torque ripple within the torque domain Torque spectrum Clicking on torque spectrum opens a window that shows the frequency spectra of torque Scales Newton meter or foot pounds lb ft for torque Metric versus US customary settings are changed under Options Setti
78. ected in line between the EP and the voltage source is recommended Ensure there is enough wire length to connect to the EP Electrical Connections Once the EP has been mounted CTs have been installed and three phase voltage lower than 1 2 1 000 VAC is made available the electrical connections may be made Connect the three CT twisted pairs to the EP current terminal block corresponding to the appropriate phase marked la Ib and Ic from right to left white wire on the right and black wire on the left for each phase Tightening torque Is 0 5 N m Connect the three voltage leads to the EP voltage terminal block corresponding to the appropriate phase marked Va Vb and Vc being sure to connect a ground to the ground position of the voltage plug Tightening torque is 9 in lb Additionally the MCC ground should be connected to either of the ground studs on the EP enclosure Caution Make sure that the voltage wiring for each phase is completely captured by its corresponding phase in the EP voltage plug i e No wire strands poking out 3 Mount the cover over the top of the voltage terminal block by either using the supplied screws and nylon spacers plexiglass cover only or by snapping in place For the plexiglass cover the screws thread directly into mounting holes in the EP case 0 437 inches above and below the top and bottom voltage terminal block mounting screws respectively Connect the MCC cable the end opposit
79. ection at MCC must be done while system is powered down 28 Depending on the kind of test to be run ensure no physical proximity to the shaft of the motor or any other moving part of the machinery 29 Ensure motor s phase connections are not positioned near ground or near each other 30 Do not touch the connections PT s CT s or any component under test while a test is being made 31 This product is grounded through the grounding conductor of the power cord if running on AC power 32 Voltage ground clip must be connected to ground when the unit is running on battery power 33 Remove the power cord from both the wall outlet and unit if it is running on battery power and not plugged into a wall outlet 34 Do not coil power cord or test leads near motor leads 35 During repairs do not substitute any parts Use only factory supplied parts to minimize safety hazards 36 This instrument is NOT approved for use in an explosive environment Motor monitoring Prior to testing the software must be set up with database structures machines must be accurately input and all thresholds for each test must be established See Chapter 3 Basic software overview for procedures After this is done the EXP4000 must be hooked up to the machine to be tested Review Chapter 9 Physical connection of the EXP4000 Connection setup wizard located on the main screen of the software 2 Ifthe connections are not correct and the machine is not a VFD
80. ed ILL Ea oe oe Phase Phase Phase E Fig 2 2 Panel Results Measurement bar indicates the severity of the area test measured Thresholds bar displays the current threshold level Each bar has an associated color level The threshold is user specified in the electric or vibration models Red warning Yellow caution Green good Blue no applicable threshold Numeric results bar displays relevant test result data such as the NEMA derating factor the load and amplitudes for the voltage phasors The results portion allows the user to access specific test results by scrolling with the left and right arrows in the test 2 24 2010 71 005 V2 EN 31 EXP4000 Getting Started field Each test result contains the date and time for the test and important numeric results Test log panel The test log tab displays trending data for the relevant test It displays the value of the monitored quantity y axis against the test numbers x axis The x axis shows the number of measurements performed for that particular motor ID Software navigation finding machines Finding machines within the EXP4000 software works similarly to Windows Explorer To i Voltage Unbalance Jo Results o ero Derating Test 071 1 00 El Date 10 28 2004 Time 11 3258 4M Fig 2 3 Test log panel find the machines to be tested simply open the machine tree located in the machine menu The highest level is the database name fil
81. ents voltages or acceleration as a function of time and frequency It provides Information on Voltage phase to ground Phase to phase voltage Phase current Vibration signal 2 24 2010 71 005 V2 EN 43 EXP4000 Basic software overview Virtual Scope File CHANNEL __ CHANNEL2 J TRIGGERING None Yab Vbe Yab Ybe Ve Vea c Vca 12 i Vb Vila vb E el lt a Va dP lb Va JP lb oF o ee TE ee V POSITION V POSITION ee gt A A cea Acq Time sec i UNITS DIV UNITS DIV 017 036 512 5125 0 08 0 68 2 in Xo 0 04 Scope Mode 1 36 02 273 Mil Sec Div 8 53 sel Spectrum Pause Exit Fig 3 16 Virtual scope The triggering function allows waveforms to appear stable on the scope by acquiring data at a particular point The triggering function establishes a value within a range of the positive and negative peaks For example a waveform oscillates from 5 V to 5 V If the t data rigger level is established at 2 V ascending slope the scope will begin to acquire at 2 V while the data Is increasing The Scope mode displays test results as a function of time or frequency Signal time Spectrum frequency The channel knobs displays test results for a specific phase in volts currents or vibration The units div knob allows a specific number of volts or amps to be displayed per division The sec div knob specifies the amount of t
82. erating the UNIT Either opening the envelope or using the software constitutes your acceptance of these terms and conditions on behalf of any party using the instrument the User If you or the User do not agree with these terms promptly return the instrument with the envelope unopened for a full refund 1 Definitions a Computer Software A Software program provided with the Instrument on CD or other physical medium for installation and use on the User s desktop computer s or servers and all updates upgrades enhancements and modifications provided directly or indirectly to the User from time to time b Documentation This User s Manual and other manuals and documentation relating to the Instrument and provided directly or indirectly to the User in the original Instrument carton or from time to time thereafter c Instrument The unit of test equipment with which this User s Manual was provided to the User d Instrument Software The software program pre loaded on the Instrument and all updates upgrades enhancements and modifications provided directly or indirectly to the User from time to time e Software The Instrument Software and or Computer Software as the context requires f Intellectual Property Rights All rights arising or protectable under the copyright trademark patent or trade secrets laws of the United States or any other nation including all rights associated with the protection of c
83. eration of the cabinet i e doors opening terminal blocks covered slide rack interference 5 The physical location of the EP does not cause an electrical environmental or safety hazard 6 An Earth ground from the motor cabinet to the EP ground stud is installed The EP may be affixed to the interior of the cabinet by any means deemed appropriate however It is recommended that a positive mounting system such as metal screws be utilized Supplied with the EP is a mounting template for the enclosure as well as self tapping metal screws The template is a 1 1 representation of the EP enclosure and can be used for location assessment as well as mounting hole placement Once the location Is decided 1 Mark the mounting holes from the template to the cabinet 2 Remove the template 3 Drill the mounting pilot holes 4 The EP enclosure may now be mounted to the cabinet with the screws provided Choosing a suitable location for the panel plug The panel plug is to be mounted on the door of the cabinet The location should be easily accessible from the outside of the cabinet providing the user an easy and obvious hookup scheme Once the location Is decided 1 Mark the center hole to the cabinet 2 Drill the center hole 3 Using whatever means deemed appropriate remove the center cutout It is recommended a 2 1 Greenlee style punch be used to create the cutout 4 Once the cutout is removed place the plug over the hole and m
84. ermines if a non balanced voltage condition exists in the machine The EXP4000 utilizes the NEMA derating curve that specifies a maximal load for each type of unbalance Harmonic Distortion Power x Options Help NP Speed 1725 Volts 230 HP 10 50 Amps 2 10 Puy Voltage Unbalance Measurement 4 20 3 00 2 00 1 00 0 00 Phase Phase B PhaseC Unbalance 0 74 Amplitudes fi 33 5 fi 35 5 fi 34 5 Average L L 233 0 Angle 0 0 fi 20 0 240 0 NEMA Derating fi 00 An AL Fig 1 2 Voltage Unbalance within the power quality domain Examines the Total Harmonic Distortion of the three single phases to neutral voltages Compares the level of Total Harmonic Distortion to the stored threshold Compares the torque speed and average stator current values of machines against previously stored values Alerts the user to values that deviated from previous operation Stator current torque and operating speed typically describe the health of a machine For example maintenance personnel should be alerted if a machine needs to run at a lower speed in order to provide the same torque The machine may have an issue caused by broken rotor bars excessive heat or different voltage conditions Total Distortion Both Total Harmonic Distortion THD and Total Distortion TD deal with quantifying the effect of non fundamental components to the voltage and current waveform Whereas the Har
85. es relating to electrical equipment designed for use within certain voltage limits as amended by Council Directive 93 68 EC and Council Directive 2004 108 EC on the approximation of the laws related to Member States relating to the electromagnetic compatibility as amended by Council Directive 93 68 EC Note due to the phenomena being observed and the material properties being measured this equipment does radiate radio frequency energy while in the active test mode Referenced Safety Standards EN 61010 1 Referenced EMC Standards EN 61326 2001 EN 55011 Class A EN 61000 3 2 EN 61000 3 3 EN 61000 4 2 EN 61000 4 3 EN 61000 4 4 EN 61000 4 5 EN 61000 4 6 EN 61000 4 8 EN 61000 4 11 the undersigned hereby declare that the equipment specified above conforms to the above Directives and Standards Signature gt A LR s AE EZ Printed Name Erik A Stolz Title Electrical Engineer 2 24 2010 71 005 V2 EN 28 EXP4000 2 Getting started Configuring software for motor data Database Management Database management Is highly important in a good predictive maintenance program It facilitates organization of periodic maintenance data The database section of the EXP4000 software allows the entry of identifications to help clarify the location of specific motors It can maintain multiple databases for organization of overall program maintenance For example if a facility has two buildings with a number of motor sights i
86. esult from its use No license is granted by implication or otherwise under any patent rights of Baker Instrument Company an SKF Group Company Warning Baker Instrument Company an SKF Group Company assumes no liability for damages consequent to the use of this product No part of this document may be reproduced in part or in full by any means such as photocopying photographs electronic recording videotaping facsimile etc without written permission from Baker Instrument Company an SKF Group Company Fort Collins Colorado Intended use of instrument The EXP4000 is intended for detection motor efficiency and physical performance deterioration and other electrical problems within electric machines by trained professionals It is intended to perform only the specified tests that this manual explains in detail Please refer to chapters in this manual concerning specific operation of the instrument 2 24 2010 71 005 V2 EN 1 EXP4000 Software Agreement Note on Software While the UNIT is a Microsoft Windows based instrument it is specially configured and optimized to perform the functions for which it was designed The loading or operation of unauthorized software may cause the instrument to malfunction or cease functioning and may void the manufacturer s warranty Software License Agreement UNIT test equipment and desktop versions Carefully read the following terms and conditions before opening the software envelope or op
87. ge Frequency ho Powar Out WW A e Terque Nem aO 33 RAM Percert Load App Power A KYA App Power B RVA New Gach gt ano Power C KA i N App Power Avg kva Reactive Power A Was Reactive Power D KvA Reactive Power C KWA Anactire Power Avy WA Fig 6 8 Right click menu 6 7 Continuous monitoring software overview A list of available items will appear Click on any of the items to create the gauge or graph 4 The graph or gauge will appear and be moveable to place wherever needed on the screen 5 Click to place the graph or gauge Channel Move Fig 6 9 Scale Editing gauges and graphs 1 Right click on the gauge or graph to be changed The following screen will pop up 2 Choose Scale and the following screen will appear auteSeae Channel w Manual Move Fig 6 10 Scale Manual 3 Choose either autoscale or manual If manual is chosen the following screen will appear Set the values appropriately and select ok Fig 6 11 Set control range 4 If Channel is chosen the following screen will appear The user can click on any of the channels and the graph or gauge will automatically change to that item 2 24 2010 71 005 V2 EN 68 EXP4000 Continuous monitoring software overview e me m oe Ann r EN naan Lu 6 00 on HUU A Or LL 0 00 IA RMS A IB RMS A IC RMS A VA RMS V VB RMS V VC RMS v I Avg RMS A V Avg RMS v I Imbal 5
88. gnature With the channel control this signal can be changed from torque to current or voltage of any one of the phases The demodulated spectra tool analyzes the dynamic behavior profile of the motor load system Fig 4 1 Demodulation zoom in 3D demodulated spectrum Marker Frequency of interest Frequency of spectrum Viewing controls Channel selector Frequency range Band projection Band scale BS SS a Dk a cee NS The main information of the demodulated panel is the 3D demodulated spectrum and the Frequency spectrum The Marker can be moved by a mouse drag and drop operation The mouse cursor changes from its normal shape to a hand with pointing index when the cursor is above the marker By keeping the left mouse button clicked and moving the mouse cursor over the point of interest and releasing the button will move the marker to the desired location The marker s location is important because It is the location at which two projections are plotted to the graphs and to the right and bottom of the 3D plot It shows the relative amplitudes of the marker s frequency for the different bands of AM demodulation The bottom plot shows the frequency cut performed at the marker s location Band A band is defined as a frequency that is center to the AM demodulation More 2 24 2010 71 005 V2 EN 53 EXP4000 Torque software overview Information on AM demodulation can be found in a multitude of textbooks on fundamentals of signals lin
89. gs may appear The first warning will appear if Autophasing is not activated and the EXP4000 realizes that the connection is mistaken for example having the current and voltage connections being in acb and abc sequence respectively The second warning will appear if Autophasing has failed due to excessive unbalances on the measured currents 2 24 2010 71 005 V2 EN 108 EXP4000 Physical connections of EXP3000 Connection setup wizard or voltages This can be from lacking one voltage signal not having properly closed a CT Selecting yes will take the user into the connection setup wizard continue test will continue testing using the physical setup and abort test will stop the test without saving any information to the database Using the setup wizard Fig 9 2 shows the setup connection wizard Become familiar with each labeled control These need to be understood in order to adjust the setup correctly 1 Current phasor controls a Controls the positioning of the phasors Each dial will spin a current phasor around the voltage phasors at the measured values of all three CT s m A pm W an 7 ey Prats n n Ye Connection Setup X Phasors Physical Connections OFF CALC OFF OFF gt p CALC ic CC Reset Amps Angle Volts Angle l 17 50 0 VA 1328 0 0 IB fia 170 0 VB fi33 8 20 0 IC 17 282 8 WC 134 8 240 0 Abort Test Continue Test Fig 9 2 Connection setup 2 Phasor diag
90. h Resistance tx mooo M If Over Current 4 la Over Current 2 _i A A SS Apply Close Fig 8 16 Edit Test Model 3 Click Apply and then Close This saves the changes to the test model Delete Test Model To delete a test model 1 Click Online Testing and then Delete Test Model 2 Choose the appropriate test model to delete from the drop down box Delete Test Model E 4 xj Select Test Model to delete Default EEE Fig 8 17 Delete Test Model 3 Click on Delete A confirmation box will appear Double check that this action is appropriate and then click on the appropriate response Looped Acquisition Looped Acquistion xi Number of Test to Perform Ho Fig 8 18 Looped Acquisition 2 24 2010 71 005 V2 EN 82 EXP4000 DC software overview The user can set the equipment to continually run in a looped mode for a specified number of tests 1 To access the looped acquisition mode click on Online Testing and Looped Acquisition 2 Highlight and type in the appropriate number of tests or use the up and down arrows to reach that number 3 Click start after set up is completed Tools menu There are two choices in the Tools menu The Motor Master tool gives the end user a research tool for motor efficiencies and workability It helps the user find motors of like size capabilities and efficiencies It will also allow the user to research motor details to
91. hat happen after if occurred General operation icons The CM3000 software has a few built in icons that supply shortcuts to certain aspects of software operation The icons include the initial operation of the software E Start recording Pause record stop Comnections scope 4S VS pS Modifying continuous monitoring tool 2 24 2010 71 005 V2 EN EXP4000 The continuous monitoring software tool is user customizable The user can set up the tool with as many of the graphs and gauges that are available along with changing these graphs and gauges to suit the user s needs This is accomplished through the right click menu This right click menu has 41 different gauges and graphs that can be added to enhance the value of information being collected Adding a new gauge or graph 1 With the cursor in the white space right click and a menu will pop up for adding a new gauge or graph 2 Click on either new gauge or new graph 3 _ _ _ e me Machre def at IA PASTA Ams v AMS 4 IVC RMS Mi 050 a y PURA 100600 y i a Ama v de VE PMA V VC RMS V t avg RMS A 0 00 Y Avg AMS Y I nba Y Inbal Th Arje deg 1B Angie deg IC Ange dea VO Are deg 50 55 Ye Ande den 05 30 35 LA Ange dez TR Aru deg W fA arg idea IC RMSJAJ 160 omy Ange Hg deg y 4005600 om o 10 Power A Kw RS A 1000 M power 1D A 000 Power C KW Total Power KW 5 4 va Time fs e bw FO PF Avera
92. hich a stimulus is of sufficient Intensity to produce an affect Torque Ripple Measure of time varying torque divided by steady state or average torque Total Harmonic Distortion Measure of harmonic content to a signal when compared to the amount of fundamental Triggering Method with which it is possible to start data acquisition when certain conditions of the signals are met VFD Variable Frequency Drive Vibration Model Defined as a group of mechanical thresholds Waveform Displays the shape of a signal with respect to time 2 24 2010 71 005 V2 EN 141 EXP4000 References 2 24 2010 71 005 V2 EN 142 EXP4000 Appendix F Technical specifications external USB interface CD R W equivalent Battery Run time up to 3 hours MS an Data link protocol Ethernet Fast Ethernet Gigabit Ethernet IEEE 802 11 b IEEE 8022 11g Power Voltage Requirements AC 110 230 V 50 60 Hz Processor Data Bus Speed 400 M Hz Processor 1 4 G Hz Ram Installed size 512 MB upgradeable to at least 2 GB Hard drive 40 GB 4200 RPM Video Sensors AC voltage clips Graphics Processor Graphics Processor 60 600A DC 10A 100A DC 4000A 7500A DC connection color coded 1 000 V maximum rated voltage DC voltage clips Set of 4 color coded 500 V maximum rated voltage Vibration sensor optional Case Environment Dimensions Power Supply requirements 2 24 2010 71 005 V2 EN EXP4000 AAA
93. ible to find deteriorating alignment problems load unbalances looseness eccentricity and cavitation by analyzing these spectra n i Lxplures Fig 1 14 V I Spectrum within the spectrum domain Harmonics The harmonics components compare the magnitude of the harmonic components to the fundamental currents and voltages of the system Bar charts for all currents and voltages display the distribution of the harmonic content on the different frequency bands E ee Se ae Fa pb the Mahre Ire Took umes peb Mache fear Peli PT e A LI q A pa ad NOS Bar Chan 30 Graph Fig 1 15 Harmonics in spectrum domain 2 24 2010 71 005 V2 EN 25 EXP4000 EXP4000 Tests Connection Domain Waveforms This window shows the waveforms for all three current and voltages for line operated mode If the EXP4000 is operated in VFD mode not available in basic software it shows the voltage and current for phase A 6 X esholds Tools Options Help Fig Connection EJ lt NP Speed 1725 Volts 230 Elec Mac HP 0 50 Amps 2 10 vibr Mia wes a Waveforms 50 0 100 0 150 0 1 1 1 1 17 202 3 225 20 rd EMO eel 25 50 75 100 125 150 175 200 msec Fig 1 16 Waveforms in the connections domain ABC SYM Comp The Symmetrical components displays the voltage current and impedance unbalance and the positive sequence accelerating and the negative sequence retarding Curren
94. ibr Mode PHASES A B c Ave Sup 3 Volt V 133 9 133 5 133 8 231 10 gt Curr A 1 8 1 8 1 9 1 8 Ava Frea 60 0 OOW ages RY YY NO NEMA Volt Unbalance 13H nema Derating Factor Speed RPM 11 747 9 2 97 Torque ft Ib 3 0 e 7 Load HP 0 5 E Load 98 7 0 0 00 I I 1710 0 1740 0 1760 0 1780 0 1800 0 Efficiency 75 RPM Torque Speed Autophase Sensors CT Selection Yes d Portable 1000 A EP 150 A No 10 A lt q Run Electrical Run Yikwetion VFD Detaiis 12 gt ne Fig 2 1 Front panel EXP4000 software A _ ar ar ar oo Te Mar Machine name Electric model LED indicates activity Test domains Display phasors Total power Average line current Average line to line voltage Line to neutral ground or line to line Voltage see Options menu Line current Electro mechanical data Currently displayed test rk RO COND UO FW PD NEMA derating factors Average frequency Hz Run electrical tests A Basic nameplate information of motor under test B Waveforms display signature of voltage and current C Displays torque time VFD operation mode or torque speed line operation mode 2 24 2010 71 005 V2 EN 30 EXP4000 Getting Started The main panel consists of three components the top menu the numeric fields center left and individual test buttons domains Numerical fields 6 10 This area displays the s
95. ified 2 24 2010 71 005 V2 EN 126 EXP4000 Troubleshooting How do connect the EXP4000 s portable CT s if have only 2 CT s installed in my medium or high voltage motor The concept of sum of currents applies in this situation 1 Connect the first two portable CT s to phases A and B 2 The third CT needs to be connected to both CT s around the other phases Make sure that the third CT totally closes around both currents of phases A and B If the CT doesn t totally close it will monitor much less current Note The third CT needs to be monitoring the SUM of both currents and not the subtraction This means that the orientation of the wires through the CT has to be such that the currents add and do not subtract If the wires are set such that the currents subtract the EXP4000 will monitor a very high current unbalance through that CT If this is the case take one of the two wires out of the CT and introduce it into the CT in the opposite direction with respect to the CT s arrow 2 24 2010 71 005 V2 EN 127 EXP4000 Troubleshooting 2 24 2010 71 005 V2 EN 128 EXP4000 Appendix C Blue results Conditions under which test show blue results Blue results are results that have no threshold comparison but give valuable information about the machine Voltage level Always for VFD mode Never in Non VFD mode Rotor bar Low load below 25 Varying frequency during acquisition High noise floor of many current
96. ime for the horizontal divisions For example 1 ms equals 1 millisecond per division The V position knob changes all displayed waveforms up or down The H position knob moves all displayed waveforms left or right The pause button stops the digital scope from acquiring in a loop and holds the last acquired condition Under the file menu there are several options for the scope The save waveforms option make possible to place the displayed data into a text file This can then be used with other software for further evaluation the panels which show knob settings Click exit to exit the scope tool View connections The load waveforms option allows the display of saved data Use the print graph function to print the currently displayed graph on the screen The print panel option will print the whole panel This includes the right portion of This view displays connections currently used The Check Connections light will illuminate red if the connections are incorrect When the connections are correct the Check Connections light will be green 2 24 2010 71 005 V2 EN EXP4000 44 Basic software overview CI x Amplitude Phase VA 123 5 lc VB 124 5 120 vc 125 5 240 IA i7 50 8 1170 Fig 3 17 View connections Transient analysis The Transient analysis mode permits capture of startup transients via voltage and current vs time and torque vs time Within Transient Analysis a submenu is available Options ar
97. ing the Baker service department or one of the service centers please have the model and serial numbers available These numbers are located on the rear of the instrument If the unit is out of warranty a purchase order will be required if the unit is returned for repair Software Agreement Virus Alert The UNIT contains computer software that Is vulnerable to damage from computer viruses Before shipping Baker SKF scanned all data to ensure the UNIT is virus free Before inserting any disks into the disk drive or connecting the UNIT to a computer network scan all disks for viruses Trademarks All other trademarks service marks or registered trademarks appearing in this manual are the trademarks service marks or registered trademarks of their respective owners 2 24 2010 71 005 V2 EN EXP4000 Software Agreement 2 24 2010 71 005 V2 EN EXP4000 Table of Contents Mepnded US i 6 ia yoa a 8 Aa aaa 1 NS PP e A RO 2 So Ware ceense Agree eM Us siz eins casas an 2 a DION Sito ns 2 A Pen eV Uae BR EROO 5 A A OPS RPE EOP E POD AP RF TRO N WS ROI nT NOP TON Pan T 5 Pra AA EAA E E E E AE 13 apor an sale nrnna aaa 13 General oae y PrecaUtions a a A A A a SN 13 MEN Iii 13 Symbols Labels 0n eau end nd 13 Other important Save wy VV alam S A ds 14 Operational Te Wali S ali ex A A E Svs late Dio 14 Technical assistance Authorized Service Centers oooconnononononono nononannononananinnonenannooonanasuonenacnoneneneso
98. ingle phase to neutral voltages or line to line voltages depending on the setting in the Options menu single phase currents average power factors average current total electrical input power and average line to line voltage 11 The five numeric fields located in the lower left portion of the center section exhibit the motor s mechanical and electromechanical operating condition 12 This text field displays the time of the current test data 13 The NEMA Unbalance displays the unbalance level of the voltage and current The NEMA Derating Factor suggests a derating percentage for the current operating voltage condition 14 Avg Frequency displays the average of the fundamental frequency during the data acquisition Domain panel The test domain buttons are located on the right side of the main panel Each test domain button allows access to Its specific test results Because each threshold equates to a specific color the EXP4000 assigns a color to the domain and testing domain buttons depending on the test result Ex f the result of the voltage unbalance test fall below the established caution thresholds the EXP4000 would assign green to the voltage unbalance button Results panels 1 2 3 i A B E Waveform E rr 5 Voltage Lewe Ea Pawn Ja Haza res 5 Tom nto Over Voltage 2 volage Sn a B ss 1000 500 cada poz a FR FSS AMS Ares 200 Peste LA TEE Re
99. is that surrounds a steady state average torque An important feature of the graph is the overall signature of the instantaneous torque torque versus time plot This signature is the result of the load requirements of the drive T kxIax If Boundaries N A blue results Results Torque ripple is too high A torque ripple in a ripple free application indicates a problem Possible problem root cause Load problem Drive problem Load level The motor Is required to deliver the load level requested by the load If there is a change in the load level the root cause of that change lies in the driven load not in the motor s capabilities ox x Results Test Log Results TestLog 110 lt eum Measurement Thresholds aes Load a 80 110 00 And Up A o 5 100 00 110 00 40 lt 0 0 100 00 62 33 Load Caution Warning It Avg 123 67 It Ripple 86 02 62 33 100 00 110 00 IFRMS 7 43 If ff 1 02 Print Close Fig 8 41 Load level 2 24 2010 71 005 V2 EN 97 EXP4000 DC software overview Function Load level displays the test history of the load Dynamic monitoring identifyies deterioration which in most cases Is gradual making trending important A gradual Increase of load can be a sign of additional friction in the driven belt system A decrease can be traced back to a gradual blockage of the inlet of a fan or a pump Changing loads can only be diagnosed w
100. ith detailed knowledge of the operating process Expertise in the particular driven load is necessary to determine whether the measured change Is meaningful for predictive maintenance Typical thresholds Warning threshold 120 lt load Caution threshold 110 lt load lt 120 Possible problem root cause In case load level is too high Load level problems are always caused by the load Possible effects Overheating Waveforms Waveform shape can be indicative of drive or motor problems For example if every sixth peak of the Vf or Va waveform is smaller than the rest it is possible that one SCR ona six pulse rectifier is not firing properly Typically there are no ripple capacitors in a DC drive so these waveforms typically are not flat In addition an entire missing tooth in the waveform could indicate a broken SCR Voltage unbalance should also be visible Because there is more inductance in the field than in the armature If should normally be relatively small high resistance with less ripple than la Ls J Fig 8 42 Waveforms Spectrum Spectra are useful for analyzing the frequency content of time domain signals Va la If Vf and torque are transformed to the frequency domain with the DFLL Digital Frequency Locked Loop and or the FFT Fast Fourier Transform 1 Click on the spectrum domain button to view the spectrum tests 2 Click on any of the test buttons to view the graphical spectrum test results Fie
101. ith these terms and conditions shall constitute sufficient cause for Baker SKF to terminate this Software License and the license granted hereunder immediately and without an opportunity to cure This subsection 2 d shall not be construed to preclude or in any way effect a finding of materiality with respect to any other provision of this Software License 3 Ownership Baker SKF as between Baker SKF and the User owns all Intellectual Property Rights related to the Software including custom modifications to the Software whether made by Baker SKF or any third party The User agrees that this Software License effects a license not a sale of the Software and that the first sale doctrine as codified in 17 U S C 109 does not apply to the transaction effected by this Software License 4 Confidential Information The Software contains proprietary information including trade secrets know how and confidential information hereinafter referred to collectively as the Confidential Information that is the exclusive property of Baker SKF During the period this Software License Is in effect and at all times after its termination the User and its employees and agents shall maintain the confidentiality of the Confidential Information and shall not sell license publish display distribute disclose or otherwise make available the Confidential Information to any Person nor use the Confidential Information except as authorized by
102. ization including eye protection high voltage gloves arc flash rated masks hoods and any required PPC Prior to opening any MCC Motor Control Cabinet ensure that appropriate arc flash protection clothing is worn 38 Ensure that appropriate lockout tag out procedures are properly understood and implemented by all personnel 39 Ensure motor s phase connections are not positioned near ground or near each other Hardware Installation NOTE It is necessary that each EP is provided 3 phase voltage not in excess of 1 000 V AC and a good ground Some switchgear installations will require this voltage to be wired from the bus cabinet to each cabinet being outfitted with an EP For motors rated at voltages higher than 1 000 V AC secondary output voltage from the PT s are acceptable as long as all three phases are present as line to line voltages and are lower than 1 000 V AC 2 24 2010 71 005 V2 EN 132 EXP4000 EP1000 installation Choosing a suitable location for the EP The EP may be mounted in a variety of locations as long as the following criteria are met 1 The EP must be installed in a cabinet or enclosure that is secured with a tool or key lock 2 Voltage and Current lines can be easily and safely ran to the EP in accordance with applicable electrical codes 3 The connector cable can reach the cabinet door and the movement of the door is not restricted 4 The EP does not interfere with or complicate the mechanical op
103. kely correct solution is to rotate the phasors to the low load position Note to go from a high load position to a low load position rotate each dial one position to the left To go from a low load position to a high load position rotate each dial to the right one position 2 24 2010 71 005 V2 EN 113 EXP4000 Physical connections of EXP3000 Connection setup wizard 2 24 2010 71 005 V2 EN 114 EXP4000 10 Example test and report generation This chapter is to give general guidelines for using the EXP4000 dynamic motor monitor It does not cover all capabilities of the machine Important safety information General Safety Precautions Note The general safety information presented here is for both operating and service personnel Specific warnings and cautions will be found throughout this manual where they apply Note If the equipment is used in any manner not specified by Baker Instrument Company an SKF Group Company the safety protection provided by the equipment may be impaired Safety term definition DANGER Indicates a hazardous situation which if not avoided will result in death or Serious Injury WARNING Indicates a hazardous situation which if not avoided could result in death or Serious Injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE This signal word addresses practices that could result in property damage but not pers
104. kers are needed BPFO BPFI and BSF and color associated lines will appear on the graph Side band frequencies can also be added to the graph by selecting the 2 24 2010 71 005 V2 EN 56 Torque software overview Create a Bearing ox Manufacturer Model BPFO EFFI BSF Oil RPM na Grease RPM NA Estimate Frequencies Cancel Fig 4 7 Create a bearing Estimate Bearing Frequencies Humber of balls f Cancel Fig 4 8 Estimate bearing frequencies My Spectrum Data Copy E xj Select Channels MV VA V VB M vc IV IA V IB Vv cC Y T Copy Time Waveforms te Copy Spectrum Data FFT Start Frequency End Frequency 0 00 3000 00 Frequency Resolution Hz 1 46 M Open File in NotePad Fig 4 9 Spectrum data copy checkbox These sidebands can be increased or decreased by using the up down arrows associated with the sidebands Copy graph and copy plot will copy data that can be placed in reports or saved to files Export data copy will export all numerical data for the spectra to a WordPad file Select the data that is needed by clicking in the checkboxes and radio buttons to customize the data file Finally by clicking on full screen graph the user can view an enlarged graph To return to regular screen press Esc 2 24 2010 71 005 V2 EN EXP4000 Torque software overview 2 24 2010 71 005 V2 EN EXP4000 58 5 VFD software VFD3000 V
105. ld Spectrum Vf and If should have similar spectra at lower frequencies As frequency increases impedance also increases the impedance is mostly inductive resulting in If spectrum beginning to decrease in amplitude at higher frequencies 2 24 2010 71 005 V2 EN 98 EXP4000 DC software overview The field circuit does not interact with the load so any issues found in the field spectra have to be the result of the voltage sources the resistance of the field or the inductance of the field A field circuit powered by rectified three phase AC should display harmonics at the following locations DC 6 12 18 etc There should be no harmonics at multiples of the second harmonic 2 4 8 etc The presence of a second harmonic multiple could be due to voltage unbalance at the input of the DC drive For low ripple applications having excessive If ripple the inductance of the field circuit could be too low This can be corrected by adding additional inductance externally to the drive and or motor field circuits 210 x 01 0 01 0 001 0 0001 A 18 05 18 06 1 07 18 08 18 09 1E 10 1E 11 1E 12 1E 13 1E 14 l 1 l pea 0 500 1000 1500 2083 2 ga ENE Fig 8 43 Field spectra Armature spectrum As with field Va and la should have similar spectra at lower frequencies However as frequency increases impedance also increases the impedance is mostly inductive As a result the la spectrum should decrease in a
106. lick on Assign Elec Test Model Select a test model by clicking on the Select Test model drop down box Once the desired test model is found click Assign Create elec test model The create elec test model command allows setting of thresholds for electrical tests When this menu item is clicked information is requested for caution and warning test levels This is useful for creating templates for motors in different service environments lt _ _ gt gt gt o E Croato Threshold ivi O Poses Condiin Machine Pedomanca Hachine Cordon Energy Arresareni Panda Commie ao Werkglet SIMS Under Voltage 2 Caution Level 595 00 WaenngLevel S Unbalince 4 CauonLewi II weregimei Voltage Harmonic Distortion 2 Coun Leet 70 Wanngle SA Voltage Total Distortion Caubon Lereel TO Warnglee Sian Fig 3 14 Create Elec Test Model 1 Click on Thresholds menu 2 Click on Create Elec Test Model 3 Type a name for the test model in the box 4 For each test enter the caution level and warning level thresholds Adjust thresholds by clicking the up and down arrows or by entering numbers in the text field Note For the Voltage Level test enter caution and warning level thresholds for over and under voltages independently from each other 5 Click Create This will save the new test model and return to the main menu 2 24 2010 71 005 V2 EN 42 EXP4000 Basic software overview Edit test
107. lue IA Angle deg Channel is gt Val IB Angle deg Channelis gt Value IC Angle deg Channel is gt Va VB Angle deg Channel is gt Value M Le Le Le te e e ke ta ke ke kele keie C M e o CE OLS ORL OLS OL OLR OL 4 Fig 6 7 Event triggers To set up triggers follow this procedure 1 Click on options then event triggers 2 Check the box for each trigger needed 3 Set the parameters needed for each trigger a Start condition set this to either greater than or less than the value Click on down arrow to reveal other choices b Start value Type the number value appropriate for this trigger c Stop condition set this to either greater than or less than the value Click on down arrow to reveal other choices Remember this must be different from the start condition d Stop value Type the number value appropriate for this trigger Remember this must be different then the start value 2 24 2010 71 005 V2 EN 66 EXP4000 Continuous monitoring software overview e Pre trigger sec Number of seconds prior to event the software records data f Post trigger sec Number of seconds post to the event the software records data Note If the pre and post triggers are set to zero the data that is recorded is just the event If these are set to greater than zero data will be recorded that gives information on what led up to the event and w
108. model The Edit Test Model menu item allows editing of the thresholds for a particular electrical test model Note Editing the default Test Model is not allowed 1 2 3 4 5 6 Click the Thresholds menu Click the Edit Test Model Click on the arrow to the right of the Select Test Model text field by scrolling through the test model list Click Edit The Edit Test Model panel will appear Make corrections or changes as needed Click on Save to complete the edits Delete test model The delete elec test model option allows deletion of any particular electrical test model which is not currently assigned to any motor ID other than the default Test Model which can not be deleted 1 2 3 4 Click the Thresholds menu Click the Delete Test Model Click the arrow to the right of the Select Test Model text field Select the desired test model by scrolling through the test model list Click Delete A warning window will appear to verify that this operation is appropriate If it is click Yes The test model will be deleted Tools menu items The Tools menu has a number of items that will assist in monitoring machines Tools Options Help Scope F7 wiew Connections Fo Transient Analysis F9 Loop Acquisition j Stator Res Estimator Motor Master IEC Efficiencies Fig 3 15 Tools menu Scope Clicking on the scope menu displays a virtual oscilloscope The virtual scope displays curr
109. monic Distortion focuses on the harmonic content alone Total Distortion focuses on all non fundamental components 2 24 2010 71 005 V2 EN 18 EXP4000 EXP4000 Tests A m Measuramant Average TD 14 40 A dad Fig 1 3 Total Distortion within the power quality domain The commonalities and differences between THD and TD are THD adds only harmonic components and divides by the fundamental TD subtracts the fundamental from the RMS and divides by the fundamental THD is defined in IEEE and NEMA standard whereas ID is not defined in these standards THD delivers reliable results for line operated machines TD delivers reliable results for all machines For all applications TD values must always result in higher values than THD Power The power window provides information to define power qualities It displays kW kVA and kVAr as well as voltages currents power factor total harmonic distortions and crest factor for voltages and currents The power details also contain the NEMA derating percentages due to the current and the voltage imbalances i F aii T THDw 01 ar THD foi 1 a ele fia ha fr E eer fa fia fa NEMA Voltage Unbalanee 2 NEMA Current Unbalanee 5 Average Fundamenial Frequency E S py da Fig 1 4 Power data within the power quality domain 2 24 2010 71 005 V2 EN 19 EXP4000 EXP4000 Tests Harmonics The Harmonic components compare the magnitude of the harmonic
110. mplitude at higher frequencies If this is not the case It is due to the machine The armature spectra is useful in identifying the following problems Raised bar Raised Mica Chattering Neutral plane problems it Torque Spectrum 5 x 0 1 0 01 2 24 2010 71 005 V2 EN Fig 8 44 Armature spectra 99 EXP4000 DC software overview Torque spectrum The torque spectrum is composed of both electrical and mechanical components The electrical component can be reduced by addressing Issues pertaining to Va form factor and armature current ripple such as voltage unbalance unsymmetrical firing of SCR s and insufficient drive pulses Some applications such as extruders require very little torque ripple In these applications it is critical that the ripple be addressed Once the electrical components of the torque spectrum have been isolated whatever Is left is a mechanical signature Armature Spectrum k 01 0 01 0 001 0 0001 18 05 18 06 18 07 18 08 18 09 18 10 18 11 18 12 18 13 1E 14 59 997 0 023051 Fig 8 45 Torque spectra Harmonics 2 24 2010 71 005 V2 EN EXP4000 Harmonics provide an indication of how much alternating current is feeding the DC current motor When a DC current motor Is operated from a rectified alternating current source rather than from a low ripple source such as a battery the performance could be affecte
111. n each it may work best if there were a database created for each building Consequences of not organizing data into databases Since the EXP4000 can be configured to store every test it ever performs an organized structure is needed to facilitate data integrity and usefulness Also creating multiple databases allows easier management of file size and archiving Plant maintenance It is common for plants to have duplicate processes with identically named motors in each process ex intake pump This can cause confusion since the motors are in different locations but have the same motor ID Take steps to make motor ID s unique For example the motor ID for process 1 should be intake pump P1 while the motor ID for process 2 should be intake pump P2 Database features The records that are stored by the EXP4000 are linked to each other hierarchically The principle record which serves as the base for linking associated records is the machine ID Information entered into machine ID and test ID records become part of the database Like other database information it can be transferred to other computer programs or other computers Navigating through the software interface Familiarity with Windows 98se Windows NT SP4 Windows 20006 or Windows XPO and basic computer skills is assumed Working with the EXP4000 software requires a general understanding of using multiple windows a variety of keyboard commands and a pointer device mouse
112. n the voltage and current phasor of phase C in degrees This number will typically vary between 90 degrees at no load to 20 degrees at full load for induction motors Z Angle Avg deg Average Angle between the voltage and current phasors of their respective phases in degrees This number will typically vary between 90 degrees at no load to 20 degrees at full load for induction motors Reactive Power C Single phase reactive power for phase C in kilo volt amperes kVAr Reactive Power Avg Sum of the three phases reactive powers in kVAr kVAr V over F It displays the instantaneous ratio of voltage level divided by fundamental frequency of the voltages For all line driven machinery this must be a constant For most VFD applications it also needs to be near a constant value 2 24 2010 71 005 V2 EN 70 EXP4000 7 Vibration software overview Vibration Models The vibration software allows the connection and analysis of vibration probe data on the EXP4000 A vibration test model is a set of thresholds used as a guide to test motors The software compares test results to the vibration model s established tolerances Under the Thresholds option assign create edit or delete vibration test models File Machine Thresholds Tools Options Help Assign Test Model Create Elec Test Model Database f Create Yib Test Model Edit Test Model Delete Test Model A Machine lc PHASES Fig 7 1
113. nces have been entered into the Create Motor or Edit Motor panels in the EXP4000 software 2 Motors can operate at low efficiencies because of their design or poor power conditions Check that the voltage level is appropriate for the motor tested Make sure voltage unbalance and voltage distortion are acceptable 3 If after performing the first two steps it is found that the motor is performing poorly further investigate the application using MotorMaster To ensure an accurate efficiency estimation the test results will only be green yellow or red if the stator resistance has been entered for the motor in the Create Motor or Edit Machine Perf X Hesulis Test Log Test Log Calculation Thresholds Losses Difference Losses Difference 1 Target Losses 50 00 And Up and Efficiency are not available for this motor design or load point 25 00 50 00 And Down 25 00 Load 70 3 Est Efficiency 56 1 Calc Losses kw 0 0 per Year 145 70 Fig 1 9 Efficiency test within the machine performance domain 2 24 2010 71 005 V2 EN 22 EXP4000 EXP4000 Tests Motor panels of the EXP4000 software Payback Period This test searches the database for motors and compares the energy expenses of the motor under test with higher efficiency motors Payback period is calculated based on the compared motor s list price the energy savings calculated according t
114. ne location icon Machine icon Icon displays the worst color from the last test on that motor If no tests have been performed the icons will be white Tests OO y Y Goodtest Green Y Caution flag Yellow anh Circle with square waveform for a VFD motor Upgrading databases from previous software versions Before the EXP4000 software can open a database from previous versions of the software it must upgrade the database This upgrade tool will pop up whenever an upgradeable database is opened It will place the file in a default directory This directory must be a separate database from the one where existing data Is stored After the database is upgraded it will automatically open in the software Note that upgrading a database does not delete the old database It allows expanded capabilities within the new software to be used while permitting the use of older versions of software on the old database There is an executable available that will automatically update all databases at once Contact Baker Instrument Company an SKF Group Company for more details Printer configuration The EXP4000 comes equipped with a set of printer drivers installed If necessary more printer drivers may be added To install a printer follow the instructions provided in the printer manual Keyboard shortcuts F1 key on the keyboard opens the loaded Help environment F2 key opens the machine tree F3 key operates the Cre
115. nerator or a load with leading currents Cange Should be between VCangie and VDangle 90 degrees Note that Induction Motors have the current lagging to the voltage Note to neglect this warning if the EXP4000 is connected to either a generator or a load with leading currents Estimated percent Load is gt 300 There may be a more practical solution with a reasonable load point 2 24 2010 71 005 V2 EN EXP4000 Possible resolution Rotate the Current phasor controls until all phasors have approximately a distance of 120 degrees 5 degrees from each other Verify that the correct CT selection was used when run electrical was pressed If the CT Selection was incorrect the user will need to abort the test and correct the selection Rotate the la current phasor dial until the red phasor is positioned correctly Rotate the Ic current phasor dial until the red phasor is positioned correctly Rotate the Ic current phasor dial until the red phasor is positioned correctly Rotate current phasors until all are correct and load estimate Is roughly where the motor is running 110 Physical connections of EXP3000 Connection setup wizard Setup wizard Suggest button The Suggest button a q EEF 7 ow 6 fF A p s yj Connection Setup Abort Test Continue Test Fig 9 3 Suggest button When the connection setup wizard appears the Suggest button is available The Suggest but
116. ngs Zooming Is possible by identifying a frequency range with the two yellow markers These markers are moved with the mouse by dragging and dropping Once the window is identified operating the Zoom button will recalculate the frequency components of the signal located between the yellow vertical markers The recalculation is done via the DFLL h This means that the narrower the window between the markers is the higher the resolution Fig 4 4 Torque spectra within torque domain To restore to the maximal bandwidth display click on restore 2 24 2010 71 005 V2 EN 55 EXP4000 Torque software overview Two white cross markers can be moved via mouse point and click They attach to the displayed frequency spectrum The marker s location is displayed in the Cursor 1 and Cursor 2 fields The cursor to the left is defined as Cursor 1 and marks the lower frequencies The difference in amplitude and frequency between both is shown in the fields Delta Amplitude Delta Frequency Right Click menu By clicking the right mouse within the graph opens the following floating menu A ee Mh A AL a Hz Unmask Electrical Freq Zoom Restore Frequency Markers Copy Graph Copy Plot Data Export Spectrum Data Full Screen Graph Fig 4 5 Right Click Menu Options has a set of three toggle settings The first one switches between Logarithmic Plot and Linear Plot for the y axis scale The second choice Units in KCPM or Units
117. nse for the Software to any third party v reproduce the Software other than as expressly authorized herein or distribute or publicly display the Software vi make the Software accessible to any Person by any means including posting on a web site or through other distribution mechanisms over the Internet vii reverse assemble disassemble reverse engineer reverse compile decompile or otherwise translate the Software or prepare Derivative Works based on the Software viii place reproduce or make available the Software on the User s computer network if the User Is only authorized by this Software License to operate the Software on a single workstation ix exceed at any given point in time the total number of network clients authorized by the applicable purchase order or ordering document to use or access the Software or x edit or modify the Software except as expressly authorized by Baker SKF including altering deleting or obscuring any proprietary rights notices embedded in or affixed to the Software c Protection of Software The User will take action by instruction written agreement or otherwise as appropriate with any person Software Agreement permitted access to the Software to enable the User to comply with its obligations hereunder d Material Terms and Conditions The User acknowledges that each of the terms and conditions of this Section 2 is material and that failure of the User to comply w
118. nt RO eT eS Re PPE Be RIOT E OE OPER Ee CRO E 78 CREAR a TOW Ola eel 78 Rehamimo a NEw Olde yenski asii a tieedevuwanesaahasienat E E O 79 eatea OW OS Eaa A ROI ON EEEE T3 Adamdan EMM iS SES A 79 PONCKE A A A NEA ETA O 80 Pabe or Foder ia 80 Omme tes OnO Menta a A A 81 Create DAS o 81 A A A ance asus aie ates area ncaa erat daniteonan ANOA 81 Determina 82 HOO DOE NCC UIS HCO Tura ds hadi tet tas rise ESA A SAA Aa 82 E Tore ee 83 A TT 83 General OPUS Sais 83 atasco ds 34 A ocasa asec saath ye Sal naa Dh nk eae ae heels Nd 84 SO Wane COS UNG 1S CROC IN arial alar AA an 84 SOWN eE TESTI Se Ni is 85 ASA AAA A AE A ES A O PR DEPORTE Te OA NE SSOP 85 Nameplate Moman evita Aen tas iis a a A A A 85 ESPTE A O 85 BOLO MI 1s SCE ria ao 86 Run leticia dador 86 NICU PO Meca a as manent ie aka a ac area abate 86 On est see scene EE ete EAEE EAE aaa tanta OEA E E EE E sucess 87 Testor ar N A A AA OEE 87 PROS NCS A A da 87 E A A cle E E EES 87 Amature voltage vella ta a E 87 DE ACHING Va CIO ULES hoo tini narra nl 88 e als A AE A A EE A ES EEA E NO 88 DEMma came VF roOublesnOO IN al AAAA O 89 Result WAS IVEDasesspeed srt tias ibi 89 Armature Voltage Form Factor ara ia Ea 91 PT PVC curente HR OP a r aS aA ea he 92 MIC ad 93 o A A de acta Mendon EAN 93 PIG ela RESISLAVICE nene sates bs acuta a a a E AE eatin 94 LOW a Cele RES Cta OTA VN gt BE MNP a Ir ne IE TON ATE TD 94 OVOP Tele E EA O sar S SI E TE J5 EE RN RO 96 TOQUE dida 9 a T o M EE
119. o the specified duty cycle of the motor the entered kWh and the latest calculated input power of the motor This test uses the premise that the comparison motor operates on average on a load point similar to the one measured All prices are in USD so the energy costs have to be specified in USD List prices are motor manufacturer s data and use the US market as a basis If the EXP4000 is used in other countries list price should be adjusted A E y ee cad Fig 1 10 Payback period within the machine performance domain Current Domain Overcurrent Compares the maximum single phase current with the nameplate data of the stator current Too much current can overstress particular phases in the machine The overcurrent test Options Help NP Speed 1725 Volts 230 HP 0 50 Amps 2 10 y Over Current esnsrasasracnsnionen Thresholds Nominal Current Measurement_ Nominal Current 144 00 100 00 Phase 17 Eff s f 0 70 Name Plate Current A Phase B rs Z Load 70 3 Nominal Current 805 Phase C re AN A a Ear Vibe i coma Fig 1 11 Overcurrent test within the current domain 2 24 2010 71 005 V2 EN 23 EXP4000 EXP4000 Tests determines if the machine might be drawing more than its rated current on one or more phases This causes excessive heat and decreasing life of the insulation Current Unbalances Unbalanced currents are frequently caused by mil
120. ode The Federal Bureau of Investigation investigates allegation of criminal infringement for enforcement Should you have any questions concerning this User s Manual you may contact Baker SKF at 4812 McMurry Avenue Suite 100 Fort Collins Colorado 80525 Telephone 970 282 1200 Fax 970 282 1010 www bakerinst com Important notice concerning warranty and repairs The warranty is void if i the UNIT is shipped without shock absorbing packing material ii the UNIT is damaged by improper use iii any party other than Baker SKF modifies the Software or loads or operates unauthorized software programs on the UNIT or iv the User has breached the Software License set forth above The User assumes all responsibility and expense for removal reinstallation freight or on site service charges In connection with the foregoing remedies Baker SKF s liability to purchaser relating to the product whether in contract or in part arising out of warranties representations instructions installations or defects from any cause shall be limited exclusively to correcting the product and under the conditions as aforesaid If the UNIT fails whether it is under warranty or not call the Baker SKF service department before returning the unit for repair If the unit needs in house repair our service staff might direct you to ship the unit to the authorized service center closest to you This might save both time and money When call
121. oltage Collect and graph field current Collect and graph armature voltage Collect and graph armature current Collect and graph transient data including start up transient Calculate instantaneous torque and graph torque ripple and torque spectrum Calculate harmonics on all voltage and current data Calculate current spectrum Calculate voltage spectrum Cursors available to analyze torque and current spectrum data Data can be exported for additional analysis with programs such as Matlab or Excel Types of problems identified with DC3000 Firing sequence and firing angle issues Voltage unbalance issues Voltage level issues Analyze voltage form factor Measure incoming power condition Failed SCR s or IGBT s Diagnose brush fire Diagnose brush chatter Diagnose drive issues Diagnose commutator problems Analyze troubleshoot response of motor circuit Analyze troubleshoot load issues Analyze troubleshoot I R issues Assists in setting neutral plane DC connections for the EXP4000 portable sensors DC sensor voltage ratings 2 24 2010 EXP4000 NOTICE The maximum rating of the EXP DC voltage circuit is 500 V 500 V is the maximum allowable voltage between any two of the four voltages and the ground clip Under no circumstance connect the voltage sensing circuit to higher voltage levels This will cause severe damage to the EXP4000 71 005 V2 EN 75 DC software overview Terminology V Armature Voltage V
122. omputer programs and or source code g Person An individual a partnership a company a corporation an association a joint stock company a trust a joint venture an unincorporated organization or a 2 24 2010 71 005 V2 EN EXP4000 governmental entity or any department agency or political subdivision thereof 2 License Related Terms a Grant of License Baker SKF grants the User pursuant to the terms and conditions of this Software License a non exclusive non transferable and revocable license to i use the Instrument Software only on the Instrument ii the Computer Software s on the numbers and types of desktop and or other computers specified elsewhere in this User s Manual iii reproduce the Software only as necessary to use it and create no more than two copies of the Software in machine readable form for back up purpose only provided in each case that the copy shall include Baker SKF s copyright and any other proprietary notices and iv utilize the Documentation only in conjunction with the use of the Software b Restrictions on Use The User shall not i permit any parent subsidiaries affiliated entities or third parties to use the Software ii grant third parties use of the Software ona service bureau application service provider or other similar basis iii rent resell lease timeshare or lend the Software to any Person iv sublicense assign or transfer the Software or this lice
123. onal injury Symbols Labels on equipment Ay Caution Indicates a hazardous situation which if not avoided could result in personnel injury and or equipment damage A Voltage level warning Located on labeling for test leads on right side of instrument 2 24 2010 71 005 V2 EN 115 EXP4000 Example test and report generation Current Input Use specified current probes EP Vibration Input Use specified EP and Vibration cables Voltage Input A AC 1000 V CAT III AN DC 500 V Fig 10 1 Safety Labels from EXP4000 Other Important Safety Warnings 10 Warning When the instrument exterior case is open the instrument is not water resistant Do not allow the opened instrument to be exposed to water Water in contact with the interior of the instrument compromises protection features and could result in serious injury or death 11 Warning Because of the voltages present the test should be conducted only by trained personnel and adequate safety precautions must be taken to avoid injury to personnel and damage to property 12 Warning Because of the dangerous currents voltages and forces encountered safety precautions must be taken for all tests Follow all corporate guidelines and those included here Due to the wide diversity of machine applications no attempt is made here to list or review all specific manifold general safety precautions However this manual includes special safet
124. oper phasing in connection save data and send to Baker Instrument Company an SKF Group Company for further tuning of Autophasing feature 125 Troubleshooting Non VFD Autophasing feature OFF Note that V Voltage is connected in abc and current Swap two CT connections Example and l in acb sequence or vice versa swap the red CT and the yellow CT s sequence do location not coincide Three power CTs are a Turn the three CTs around factors details a facing the wrong direction Reverse direction of arrow power are b connected to the wrong phase b Exchange cyclical locations of negative or load CTs red to yellow yellow to blue Is very wrong blue to red If results still not Far too high or correct perform this step one more far too low time Otherwise check a Frequently Asked Questions The EXP4000 shows the wrong speed It displays the operating speed as synchronous speed 3600rpm 1800rpm 1200rpm 900rpm etc for 60Hz or 3000rpm 1500rpm 1000rpm etc for 50Hz operation However the motor is running at speeds lower than that What is the problem When creating a new machine the nameplate speed needs to be entered into the speed field of the Create Machine or Edit Machine panel If the synchronous speed was entered then the EXP4000 expects to be testing a synchronous machine and not an Induction machine For a synchronous machine displaying the synchronous speed is correct 1 Click on m
125. ort will automatically create and auto fill into a rtf Rich Text File document This document can be edited to suit the users needs i e logos notations of tests network capable etc These annotations can be made in the report through normal text editor functionality Automatic generation of reports Results for tests conducted with the EXP4000R are automatically saved Reports can be generated from this data providing pass fail data numeric data and appropriate waveforms from tests Charts trend this data which is logged with test dates Analysis of test results over time Is a key tool in a predictive maintenance program Printing reports directly from results panel single report HP 10 50 Voltage Level Results Test Log Zoom Info Thresholds Over Voltage Measurement Over Voltage 24 00 20 00 15 00 10 00 5 00 0 00 Phase Phase B Phase C Amplitudes i339 1335 133 8 Average L L 231 7 a Rated L N fi 32 8 Rated L L Fig 10 12 Single report generation 1 Click on test domain button wanted i e power quality machine performance current spectrum torque connections VFD details or vibration if option available 2 Press desired test button for the test wanted For this example the power condition domain is being selected i e voltage level voltage unbalance harmonic distortion total distortion power and harmonics 3 Press prin
126. ot position motor phase connections near ground or near each other 6 Do not touch the connections PT s CT s or any component under test while a test is being made 7 This product is grounded through the grounding conductor of the power cord if running on AC power 8 Voltage ground clip must be connected to ground when the unit is running on battery power 9 Remove the power cord from both the wall outlet and unit if it is running on battery power and not plugged into a wall outlet 10 Do not coil power cord or test leads near motor leads 11 During repairs do not substitute any parts Use only factory supplied parts 12 This instrument is NOT approved for use in an explosive environment 2 24 2010 71 005 V2 EN 14 EXP4000 Safety equipment warnings and CE compliance statements Technical assistance Authorized service centers For all service centers please visit our website at www bakerinst com and click on Representatives Service centers will be marked with asterisks Accessory interconnection and use Several accessories are available for the EXP4000 These accessories are listed in following chapters in the manual They are to be used only as instructed Intermittent operation limits At this time there are no intermittent operation limits for the EXP4000 unit Cleaning amp decontamination The EXP4000 should be kept clean and in a dry environment To clean the unit wipe with a clean water dampened cloth Do
127. ows waveform shape Load and torque are plotted versus time Exit By clicking this button the software will exit to the desktop Test Domains The right side of the screen has a set of test buttons known as domains Click on each individual button to see a subset of buttons and several test results screens Drive Armature voltage level field voltage level armature voltage form factor armature current ripple Machine Armature current level high field resistance low field resistance field current level Load Torque ripple load level Waveforms Results only Spectrum Field spectrum armature spectrum torque Spectrum Harmonics Results only Fig 8 29 Domains Results Green Machine running within tolerances No action needed Yellow Machine has exceeded a caution threshold Action should be taken to avoid future problems Red Machine has exceeded a warning threshold Action needs to be taken to correct problem Blue No applicable thresholds Drive The Drive domain observes the upstream power Poor power condition will expose the motor to unnecessary stress 1 Click the Drive button to view the domain tests 2 Click on any test to view the results or test logs Armature voltage level Va Arm Voltage Level Yoltage PRT 3 io x Arm Voltage Level Yoltage Ll a 4 io x Results Test Log Results Test Log
128. power 9 kVA values for phases A B and C in kilo volt amperes Displays single phase reactive power for phases A B amp C and sum of the three phases in kilo volt amperes Z angles Displays the angle between and current phasors of phase A B C and the Average Angle This number will typically vary between 90 degrees at no load to 20 degrees at full load for induction motors Machine This view displays power out torque speed and percent load The power out Is the mechanical output power the torque Is the estimated torque in Nm or lb in the speed is the estimated speed of rotation of the shaft In RPM and finally the percent load is the output load with respect to the motor s rating In percentage New view The user can create a custom view to display the items necessary to their operation 2 24 2010 71 005 V2 EN 65 EXP4000 Continuous monitoring software overview Options The options menu has two items to choose from the graph plot mode and event triggers Graph Plot Mode Within the graph plot mode choose from sweep or continuous When operating in sweep mode a red bar will sweep from left to right across the screen and start again at the beginning Stream File Machine Tools View Options Help Graph Plot Mode gt Sweep Event Triggers Continous Fig 6 6 Options Torque N m In continuous mode the tool will continue to gather data and the screen will change as it reaches the far si
129. pproved for use in an explosive environment Physical Setup of EXP4000 with portable sensors 1 Connect the voltage clip ons to the voltage port on the EXP4000 2 Connect the marked current clamp ons to the current signal port on the EXP4000 3 Turn on power to the laptop 4 Double click the EXP4000 icon to start the program To connect the EXP4000 to the MCC 1 WARNING To minimize risk of electric shock make sure the motor is off Open the panel of the MCC 2 Connect a voltage clip on to each phase of the breaker 3 Attach one current clamp on per phase Both the current and the voltage sensors of the EXP4000 are designed for low voltage AC Voltage sensors are rated for 600 V DC Voltage sensors are rated for 500 V Attach Hall Effect CT s and DC Voltage Sensors for DC Motor testing applications In order to measure medium or high voltage motors CT s and PT s are required In this case the 2 24 2010 71 005 V2 EN 107 EXP4000 Physical connections of EXP3000 Connection setup wizard current clamp ons and voltage clip ons have to be connected to the CT s and PT s on the customer s site NOTE Make sure the current direction arrow points in the direction of the load when connecting current clamp ons Voltage clip ons and current clamp ons should be connected to the cold side of the breaker 1 The voltage clip ons and current clamp ons should match color wise on each phase Ex The yellow voltage clip on should be at
130. quipment required by your organization including eye protection high voltage gloves arc flash rated masks hoods and any required PPC 2 24 2010 71 005 V2 EN 106 EXP4000 Physical connections of EXP3000 Connection setup wizard Prior to opening any MCC Motor Control Cabinet make sure that appropriate arc flash protection clothing is worn 14 Make sure that appropriate lockout tag out procedures are properly understood and implemented by all personnel 15 WARNING To minimize risk of electric shock every connection at MCC must be done while system is powered down 16 Depending on the kind of test to be run make sure no physical proximity to the shaft of the motor or any other moving part of the machinery 17 Make sure motor s phase connections are not positioned near ground or near each other 18 Do not touch the connections PT s CT s or any component under test while a test Is being made 19 This product is grounded through the grounding conductor of the power cord if running on AC power 20 Voltage ground clip must be connected to ground when the unit is running on battery power 21 Remove the power cord from both the wall outlet and unit if it is running on battery power and not plugged into a wall outlet 22 Do not coil power cord or test leads near motor leads 23 During repairs do not substitute any parts Use only factory supplied parts to minimize safety hazards 24 This instrument is NOT a
131. r the operating speed prior to performing electrical measurements Override Speed Estimate Override speed ab Seah em Dn Cancel Fig 3 27 Override Speed Estimate Electrical acquisition options Increase resolution on Rotor Bar test For low slip motors it will increase the probability of finding a problem Note should be used in constant load application Electrical Acquistion Options Fig 3 18 Electrical acquisition options 2 24 2010 71 005 V2 EN 49 EXP4000 Basic software overview Spectrum acquisition options Control data acquisition settings for the frequency spectrum analysis from this panel The left tab max frequency Hz sets the maximal displayed frequency of the acquired signal On the right the FFT lines tab controls the numbers of frequency bins lines that are displayed in the Initial spectrum display Spectrum Acquistion Options l l l Less More FMA Hz 100 00 5000 00 1000000 1500000 2093300 3000 00 Lines of Resolution 048 Frequency Resolution 0 183 Fig 3 29 Spectrum acquisition EP acquisition options f the EXP4000 is being used for quality control to test motors the EP can be adapted to a one EP for many machines instead of a one to one relationship ME EP Acquistion Options When Acquiring data from an EP te Run the electrical test using the currently loaded motor OK Cancel Fig 3 30 EP Acquisition
132. ram a A visual interpretation of the setup for easier understanding of the necessary adjustments 3 Warning box a Displays warning about current phasor setup May indicate an improper setup 2 24 2010 71 005 V2 EN 109 EXP4000 All Current Phasors should be 120 degrees apart CT Selection may be incorrect Red CT may be incorrect Blue CT may be incorrect Yellow CT may be incorrect Warning Load estimate is unusually high phasor setup may be incorrect Physical connections of EXP3000 Connection setup wizard Troubleshooting CT connections Reason for error Current and voltage phasors should be 120 degrees apart for example abs la angle lb angle 120 Remember we are in a 360 degree system so using the above example bange 52 7 300 0 Dangle 412 7 l nge 273 6 Dangle CEN 119 1 120 degrees The measured amps are below 10 of nameplate amps for the motor Note that usually the no load currents surpass the 30 of nameplate rating laange Should be between Va angle and Vaangle 90 degrees Note that Induction Motors have the current lagging to the voltage Note to neglect this warning if the EXP4000 is connected to either a generator or a load with leading currents IDangie Should be between Vb angie and VDangle 90 degrees Note that Induction Motors have the current lagging to the voltage Note to neglect this warning if the EXP4000 is connected to either a ge
133. rves the right to pursue any state law remedies including contractual remedies or remedies under federal laws or both The User consents to exclusive jurisdiction in either state or federal courts in Colorado or both as appropriate and agrees that the prevailing party shall be entitled to its attorney fees and costs No decision act or inaction of Baker SKF shall be construed to be a waiver of any right or remedy and pursuit of any state or federal causes shall not be deemed an election or remedies In the event of any provision of this Software License shall be deemed unenforceable or void or invalid such provision shall be modified so as to make it valid and enforceable and as so modified the entire agreement shall remain in full force and effect This Software License sets forth the entire understanding and agreement between the parties and no written or oral representative of any kind whatsoever shall in any way modify or expand the terms of this User s Manual 2 24 2010 71 005 V2 EN EXP4000 In the event of any conflict or inconsistency between the terms of this Software License and any Documentation this agreement shall preempt such documentation to the extent Inconsistent WARNING All material associated with this Software License is copyrighted material Federal law provides severe civil and criminal penalties for the unauthorized reproduction distribution or use of copyrighted materials Title 17 United States C
134. s essentially torque ripple free Some applications for example extruders do only function properly if the supplied torque Is sufficiently constant An excessive Va form factor may cause excessive la ripple resulting in additional commutator sparking 2 24 2010 71 005 V2 EN J1 EXP4000 DC software overview Armature Current Ripple Per ox Pata Test Los fead Tem Le Measurement Thresholds la Ripple E ps i E q 300 And Up a les ti 6 3 00 0 k Bet eee Bt o Fig 8 33 Armature current ripple Function This is current that produces no torque yet produces heat Primarily la ripple is the response of the circuit to the armature voltage AC components The inductance of the motor and any additional users supplied inductance can smooth out the armature current ripple at least to some extent A reduction in the RMS armature current ripple reduces the heating of the motor while a reduction in peak to peak armature current ripple improves the commutating ability of the motor la la max min la Ripple Factor lad yp Typical thresholds Warning threshold 2 5 lt la ripple factor Caution threshold 6 0 lt la ripple factor lt 2 5 Standards NEMA MG 1 Section 1 14 61 DC machine la ripple troubleshooting Result Armature current ripple is too high Possible Root Cause Va Form is too High Drive Malfunction Timing of SCR s is Wrong High AC
135. s x Default Directory By default all databases will be looked for and placed at this location C WINNT Profiles All Users Application Data Baker Instr Open Folder Location Browse The default type of database to create Default Type Access Database mdbx Fig 8 21 User options Database options Access Database mdb Sql Express Database mdf or Sql CE Database bic Archive This option allows the user to set the location of where archives are stored This is an important feature to remember if ever looking for or needing to locate an archive Also the Explorer creates a large amount of data points These data points can create large databases of many mega bytes Within this option menu the Max Archive Size can be set so that the data can be sent to different devices without issue If the database Is larger than the archive max size the software will break the file size to appropriate pieces and archive all of the data User Options xi General Database Archive Default Directory By default all archives will be looked for and placed at this location CD ocuments and Settings All Lisers Application Data B Open Folder Location Browse Max Archive Size When Creating archives they are split at the size specified here Cancel Apply Fig 8 22 Options menu Archive 2 24 2010 71 005 V2 EN 84 EXP4000 DC software overview Software
136. ser a general knowledge of how the EXP4000 software Is used and navigated It will step through each of the menus and provide procedures for setting up for data gathering File menu items The File menu allows the user to upload and save motor data files Under the file menu are the following options Database Print Summary Report Reports and Exit File Machine Thresholds Too Database Print Summary Report Reports Chrl F2 Exit Fig 3 1 File menu Database The Database command allows the user to open create a new close an existing or delete a database To create a new database 1 Click on the file menu 2 Click on database and choose new 3 Type the name of the new database in the space available 4 Click ok The EXP4000 will then create the database It will fill in the pertinent information on the screen including database name and default information Default information changes are made through the creation and assignment of electrical models in the threshold menu To open an existing database 1 Click on the file menu 2 Click on Database and select Open 3 Select the database to open 4 Click and select open or double click on the file to open Note Changing databases during operation is allowed by using the open an existing database procedure Note Database open will not open an archived database To open an archived database either double click it in Windows Explorer or click Machine Tre
137. sition contains two submenus continuous and timed loop acquisition continuous mode will run as many consecutive tests as specified with no interval between tests Continuous Loop Acquisition Complete 0 Remaining lo Fig 3 20 Continuous Loop Acquisition Timed mode allows the user to specify a number of continuous looped acquisitions to be repeated in intervals between tests that are user specific The user can chose the start time to elther be immediate or at a specific time and date Ending the testing can be similarly chosen Current Date Current Time 01 06 2006 Every sh 0 Minute s v Starting Now Ending when Stop It Fig 3 21 Time looped acquisition Stator resistance estimator The Stator Resistance Estimator is necessary to make the efficiency estimation as accurate as possible Fill in the necessary information and click on Estimate Resistance to obtain this calculation Then click on Close and this calculation will be used on the current machine In the field if a Kelvin bridge is not available this will give a rough estimation of the resistance of the machine The value for stator resistance can be overridden in the Machine Edit Machine motor design screen 2 24 2010 71 005 V2 EN 46 EXP4000 Basic software overview a Stator Resistance Estimator E X Fund Freg Nameplate Speed 60 00 1790 00 HP Amps 00 em Stator Resistance Estimate 0 090723 Estimate Resistance Fig 3 2
138. st model by scrolling through the test model list 3 Click Edit The Edit Vibration Test Model panel will appear Make corrections as necessary 4 Click Ok to save changes Select Test Model Select Test Model Test Vib Model Ta s Cie Wanna Velocity 0 15 0 35 Percent Diff 20 00 30 00 Fig 7 4 Edit vibration test model w Vibration Vibration VIBRATION VELOCITY IN SEC PEAK Caution Level 0 15 WamingLevel BB Operatin eae PATTERN DIFFERENCE Caution Level 2 20 00 Warring Level 300000 Cancel Fig 7 5 Edit vibration test model panel 2 24 2010 71 005 V2 EN 72 EXP4000 Vibration software overview To delete a vibration test model 1 Click on the Thresholds menu Click or press on the Delete Vibr Test Model menu item 2 Click on the arrow to the right of the Select Test Model text field Select the desired test model by scrolling through the test model list 3 Click or press Delete A confirm dialog box will appear Click Yes or No Select Test Model Select Test Model Test Vib Model Test Caution Warming Welocity 0 15 0 35 Percent Diff 20 00 30 00 Delete Fig 7 6 Delete vibration test model 2 24 2010 71 005 V2 EN EXP4000 73 Vibration software overview 2 24 2010 71 005 V2 EN EXP4000 74 8 DC software overview DC machine Dynamic analysis software DC summary of tests amp features Collect and graph field v
139. t 2 24 2010 71 005 V2 EN 121 EXP4000 Example test and report generation Printing reports from the summary page 1 Click file and then print summary report The summary report dialog box will pop up 2 Click in each of the print test toggle boxes that are needed to print 3 Click print Ms Machine Performance Report iz Tine Date E 271272002 11 39 53 PH Baker EXPLORER Database test Test Model default elec Memo Location Basement iw Test By Building Alamo C SST est Fr Machine default Serial Mo 200 HP Manufacturer EA RPM E 725 Volts Amps 2 1 0 Serv Fact y Stator Res L L 32 00E 0 Ohms Frame Insulation F Speed RPM Torque Ripple Load 7 Efficiency 3 1747 9 14 90 48 7 75 0 Test Y alue Caut Level Warn Level Status Over Voltage Good Voltage Unbalance Good Harm Distortion as 700 w Good Total Distortion Good Over Current Good Eff Serv Factor pose iww 12500 Good Rotor Bar Good Up Condition ow 20 m God Losses N A Payback T FT Main Panel PP Energy Assessment T Power Condition Report Machine Performance Report Machine Condition Report Load Reports 7 7 E Cancel Fig 10 12 Print summary report Note If there is more than one report within the domain chosen they will automatically print in order Printed reports can be placed on letterhead or other print materials to obtain a professional written report 2 24 2010 71
140. t voltage and impedance information SEE Connection ES NP Speed 1725 Volts 230 Elec Moc HP 0 50 Amps 210 vibr Ma etm y Symmetrical Components E ES ABC Domain sols Options Help Components Domain Amplitude Phase Unbal Amplitude Phase Ya 1335 foo val foo 2085 A vb has fao fore va2fieas eoo Ve fas f2400 J lal fos fisa9 it a fiz faro laz fie aio Ib rs 70 0 5 56 Ic fis fiso o Za 78 5 0 0 Zb 74 7 0 0 4 91 Ze 71 3 0 0 Zal 21 21 8 Za2 2 781 Phase Values Dependent On is Proper Sensor Connections eee ble 1000 A B mo O Fig 1 17 ABC SYM Comp within the connection domain Phasors The Phasors window shows the a b c phasors for voltages and current in line operated mode In VFD Mode not available in basic software it shows the instantaneous current phasor versus the instantaneous voltage phasor 2 24 2010 71 005 V2 EN 26 EXP4000 EXP4000 Tests Fig 1 18 Phasors within connection domain 2 24 2010 71 005 V2 EN EXP4000 el EXP4000 Tests Declaration of conformity Manufacturer s Name amp Address Baker Electrical Instrument Company an SKF Group Company 4812 McMurry Ave Fort Collins CO 80525 USA Equipment Description On Line Motor Monitor Equipment Model Designations EXP4000 Application of Council Directive 72 23 EC on the harmonization of the laws related to Member Stat
141. tached to the same phase as the yellow current clamp on 2 Prior to energizing the motor exercise extreme caution to make sure that no terminals or clip ons touch each other or touch ground Energize the motor To connect the EXP4000 to the motor terminals 1 WARNING To minimize risk of electric shock make sure the motor is off 2 Connect the current clamp ons and voltage clip ons to the terminal box 3 NOTE Make sure current direction arrow points in the direction of the load when connecting current clamp ons 4 The voltage clip ons and current clamp ons should match color wise on each phase Ex The yellow voltage clip on should be attached to the same phase as the yellow current clamp on 5 Attach one voltage sensor to each phase 6 Exercise extreme caution to make sure that no terminals or clip ons touch each other or touch ground when energized Physical Setup of the EXP4000 with EP s Note See Appendix D for installation instructions for EP s 1 Connect the EXP4000 end of the mixed AD cable to the MCC port on the EXP4000 2 Connect the other end of the mixed AD cable to the MCC plug 3 Set the sensors option of the main panel to EP 4 Click on run electrical Disconnecting the EXP4000 1 WARNING To minimize risk of electric shock turn the motor off and allow it to de energize Connection setup wizard Autophasing messages When performing an electrical test on a line operated motor one of two warnin
142. tested Within the online testing menu is the ability to create edit or delete DC test models These models contain thresholds for both caution and warning levels Online Testing Tools Help Create Dc Test Model Edit Test Model Delete Test Model Acquire EP Serial Numb Looped Acquistion Timed Looped Acqustior Sl Options Fig 8 14 Online testing menu Create DC test model 1 Click Online Testing and then Create Dc Test Model 2 Under Test Model Name type in an appropriate name for the test model Name appropriately for the application 3 Change any of the threshold levels that are appropriate by highlighting the threshold level and typing in the appropriate number Note Warning levels must be higher than the caution levels create Test Model xj Test Model Name Load D Low Resistance If Over Current la Over Current la Ripple Ya Form Factor VE Over Voltage 2 Va Over Voltage Z Fig 8 15 Create new test model Edit test model 1 Click Online Testing and then Edit Test Model 2 Choose the Test Model to be edited from the list under Select Test Model to Edit Change necessary items 2 24 2010 71 005 V2 EN 81 EXP4000 DC software overview Select Test Model x Select Test Model to Edit I Default Test Model Name o efault Con tevet Wing Level Load Low Resistance x soco ME Hig
143. testing screen The following description of the DC3000 software will aid in understanding how data is gathered 21 14 JW ft 16 Hp Fig 8 23 Main screen DC3000 CT selection On the top of the screen is a row of CT selections one for the Field CT and one for the Armature CT There are two selections in each The Field CT is either 10A or 100A whereas the Armature CT is either 60A or 6004 ah CT Selection 10 100 60 600 Field 1004 Armature 604 Fig 8 24 CT selection Nameplate Information The information listed in the top portion of the screen is from the nameplate information that was entered when the machine was created This information is for reference for what was originally entered for the machine thee IT D 100 Ya 5000 M mo g Tew EDAM Ma som ff w20 NI es Haid Dejad lt Fig 8 25 Nameplate info Center Screen Y A VF IA IF 100 100 100 100 AN YA 50 A Pa 30 130 50 130 40 130 50 130 331 35 V 324 84 V 306 57 4 6 95 4 Torque felb 638 92 Waveforms Load Hp 131 67 Load 52 67 Ya If 62 43 Fig 8 26 Center main screen 2 24 2010 71 005 V2 EN 85 EXP4000 DC software overview rid Percentage of Synchronous Speed VA Armature voltage percentage VF Field voltage percentage IA Armature current percentage IF Field current percentage Torque ft lb Torque in foot pounds torque N m
144. the voltage C in volts Average of the root mean square values of the 3 phases currents in amperes This number will typically be between 30 and 110 of nameplate current Imbal Current unbalance in For machines under load this value is typically smaller than an eighth of the voltage unbalance V Imbal Voltage imbalance in Angle between the current phasor of phase A with respect to the voltage phasor of phase A which is locked at O degrees This number is equal to Za angle phase A in degrees This number is Zb angle degrees away from Vb angle phase A in degrees This number is Zc angle degrees away from Vc angle VB Angle deg Angle between the voltage phasor of phase B with respect to the voltage phasor of phase A in degrees This number should typically be within 3 degrees from either 120 or 240 degrees VC Angle deg Angle between the voltage phasor of phase C with respect to the voltage phase of phase A in degrees This number should typically be within 3 degrees from either 120 or 240 degrees ZA Angle deg Angle between the voltage and current phasors of phase A in degrees This number will typically vary between 90 degrees at no load to 20 degrees at full load for Induction motors ZB Angle deg Angle between the voltage and current phasor of phase B in degrees This number will typically vary between 90 degrees at no load to 20 degrees at full load for induction motors ZC Angle deg Angle betwee
145. this Software License The User shall not disclose the Confidential Information concerning the Software including any flow charts logic diagrams user manuals and screens to persons not an employee of the User without the prior written consent of Baker SKF 5 Limited Warranties Disclaimer a Baker SKF s sole and exclusive warranties with respect to the Instrument and Software are set forth in this User s Manual b EXCEPT AS SET FORTH IN THIS USER S MANUAL AND TO THE EXTENT PERMITTED BY APPLICABLE LAW ALL EXPRESS AND OR IMPLIED WARRANTIES OR CONDITIONS INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTABILITY MERCHANTABILITY OF A 2 24 2010 71 005 V2 EN EXP4000 COMPUTER PROGRAM INFORMATIONAL CONTENT SYSTEM INTEGRATION FITNESS FOR A PARTICULAR PURPOSE AND NON INFRINGEMENT ARE HEREBY DISCLAIMED AND EXCLUDED BY BAKER SKF 6 Limitations on Liability a Limitations and Exclusions IN NO EVENT WILL BAKER SKF BE LIABLE TO LICENSEE FOR ANY DIRECT INDIRECT INCIDENTAL CONSEQUENTIAL PUNITIVE OR OTHER SPECIAL DAMAGES LOST PROFITS OR LOSS OF INFORMATION SUFFERED BY LICENSEE ARISING OUT OF OR RELATED TO THE INSTRUMENT OR THE USE OF THE INSTRUMENT FOR ALL CAUSES OF ACTION OF ANY KIND INCLUDING TORT CONTRACT NEGLIGENCE STRICT LIABILITY BREACH OF WARRANTY OR CONDITION AND STATUTORY EVEN IF BAKER SKF HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES THE PRECEDING EXCLUSION AND DI
146. thresholds Warning threshold 120 rated lt la Caution threshold 110 rated lt la lt 120 rated DC machine la troubleshooting Possible problem root cause Va level is too high Excessive torque is demanded by the load Armature may have stalled No current in the field Possible Effects Brush fire Commutator brush damage 2 24 2010 71 005 V2 EN 93 EXP4000 DC software overview High Field Resistance Function Comparison of calculated field resistance to field resistance at rated conditions PIES gn Field Resistance ES Results Test Log Results Test Log Measurement Thresholds Ls Field Res Hot Pe A m 120 00 And Up 1004 go O 5 50 110 00 120 0 5 i Ct zai 0 0 0 110 00 co Field Res Hot Caution Warming ee o es 557 Pres 110 00 120 00 IF 2 12367 rf 102 O ates 1 ime Close Print Close Fig 8 36 High field resistance Typical thresholds R V rated fHot I frated Warning thresholds 120 Ruo lt R Caution thresholds 110 Rmo Re 120 Ruot Result Field resistance is too high DC machine Field Resistance troubleshooting Possible problem root cause High temperature High contact resistance Small copper Possible cause Shortened insulation life Low field resistance Function The calculated field resistance is compared to field resistance at rated conditions extrapolated to the lower boundary of the insula
147. ting the motor prior to testing 1 Click on Acquire EP Serial Number 2 The software will notify you if the procedure was successfully completed Reset EP serial number An EP can be unassociated with a machine in order to re associate the EP to a newly installed machine 1 Click on Reset EP Serial Number This will unassociated the EP 2 To re associate another machine with this EP do the Acquire EP Serial Number procedure Thresholds menu An electrical test model is a set of thresholds used as a guide against which the machines will be tested The EXP4000 compares test results with the electrical model s predetermined tolerances Thresholds Tools Options Help Assign Test Model Create Elec Test Model Create Vib Test Model Edit Test Model Delete Test Model Fig 3 12 Thresholds menu 2 24 2010 71 005 V2 EN 41 EXP4000 Basic software overview Assign test model The assign test model option allows the designation of an electrical test model with which to test motors tana A ae xi Select Test Model default elec Caution Over Voltage 10 00 20 00 Under Voltage 5 00 10 00 Voltage Unbalance 2 00 3 50 TH w 00 9 00 Total Distortion 10 00 12 00 Over Current 110 00 120 00 Eff Serv Factor 1 10 1 23 Rotor Bar 45 00 36 00 Op Condition 20 00 30 00 Efficiency 25 00 50 00 Payback Period 60 00 4 00 cos Fig 3 13 Assign test model Click on the Thresholds menu C
148. tion class See high field resistance AS R f l 2 24 2010 71 005 V2 EN 94 EXP4000 DC software overview 1011 EE I lolas Results Test Log Results Test Log 160 Measurement Thresholds Field Res Cold 126 09 Nameplate be N o i o o Field Res Cold Caution Warning 126 03 90 00 80 00 Rf Est 43 94 Nameplate Res 34 85 Date Time It 123 67 IF ff 1 02 Print Close Fig 8 37 Low field resistance Typical thresholds Ricota R fenon X AT Where AT per unit resistive increase for copper going from ambient temperature up to hottest allowable temperature for that insulation class Warning threshold 80 Rio gt Re Caution threshold 90 Ria gt 80 Ricota DC machine Low Field Resistance troubleshooting Result Jurn to turn short Field winding is below NEMA ambient temperature 40 C Possible effects Shortened motor life Motor was very recently started Ambient temperature is very much below 40 C Field current level Function If level corresponds to the current flowing through the field winding Note It is critical that the field current never falls too low or moves through the zero point otherwise the motor could over speed or stall Nr Cureetera AA alot 4 Heade TestLog Measurement Thresholds i If Level 9 i Leet Caution Pin AT Lasa 2 24 201
149. tion of this Software License and 3 Software Agreement the licenses granted hereunder the User shall return to Baker SKF at the User s expense the Computer Software and all copies thereof and deliver to Baker SKF a certification in a writing signed by an officer of the User that all copies of the Computer Software have been returned to Baker SKF and that the User has complied with the requirements of this Section 7 c 8 Assignment The User may assign this Software License in connection with the sale or other transfer of the Instrument provided that the transferee agrees in writing to be bound by the terms of this Software License Except as authorized by the preceding sentence the User shall not assign or otherwise transfer the Software or this Software License to anyone including any parent subsidiaries affiliated entities or third Parties or as part of the sale of any portion of its business or pursuant to any merger consolidation or reorganization without Baker SKF s prior written consent Any assignment or transfer effected in violation of this Section 8 shall be void ab initio and of no force or effect 9 General The validity and interpretation of this Software License shall be governed by Colorado Law except as to copyright and other proprietary matters which may be preempted by United States laws and international treaties In the event of any violation of this Software License Baker SKF rese
150. to speed or torque control 2 24 2010 71 005 V2 EN 90 EXP4000 DC software overview Armature Voltage Form Factor Function Form Factor is defined as lc I ic1xi Results Test Log Results Test Log Measurement Thresholds la Ripple l 43 948 Form Factor p u Mm E dan E 1 Va Form Factor Caution Warning ffla 1 01 fia 1 08 1 08 2 00 3 00 fF If 1 02 fE vf 1 32 eaae Close Fig 8 32 Armature Voltage Form Factor a Va Form Factor A Average This Is a representation of how much Va differs from a pure DC signal The closer Va form factor is to 1 0 the theoretical minimum the cleaner the signal Va form factor greater than 1 0 indicates AC current components in the armature and could mean more losses Typical thresholds The following boundaries apply to DC motors operating from a rectified AC supply Warning thresholds 120 Va_Rated 80 Va_Rated Caution thresholds 110 Va_Rated 90 Va_Rated Standard NEMA MG 1 Section 1 12 64 DC Machine Va form fact troubleshooting Result Va form factor is too high Possible problem root cause Excessive voltage unbalance feeding the drive Unsymmetrical firing of the drive s armature circuit switches Drive s number of pulses too low Possible Effects The drive s supply introduces excessive variations in the motor s armature current This creates excessive torque ripple for applications defined a
151. ton s purpose is to offer reasonable solutions in error mitigation see Fig 5 2 If there is more that one realistic solution the user will be prompted about load level A selection of a high load scenario 90 and higher or a low load scenario 20 and lower can be made This dialog rarely pops up Note This high load and low load scenario may be an indication of incorrectly entered nameplate data Two CT solution My Connection Setup x Phasors Physical Connections de g ta OFF E CALC OFF a CALC OFF CALC IC REJ Amps Angle Volts Angle l 17 50 0 VA 1328 foo IB fre 164 5 VB 133 8 120 0 Ic fig 290 0 ve 134 8 240 0 Abort Test Continue Test Fig 9 4 Connection setup The two CT solution is based on Kirchhoff s law of currents The sum of currents into a node is equal to zero Note Calculating the current of the third phase is only valid while there is no noticeable ground current so la Ib Ic e IG e O This is typically the case however a high impedance ground system with one grounded phase is an exception A 2 CT setup is needed if unable to physically connect all three CT s if all three CT s are connected but one did not close or it is connected to a wrong wire etc If 2 or more CT s are not connected then the test should be aborted and the CT s manually adjusted 2 24 2010 71 005 V2 EN 111 EXP4000 Physical connections of EXP3000 Connection setup wizard In
152. two CT connections Example and l abc and current in acb swap red and yellow CT positions sequence do sequence or vice versa not coincide Speed negative Voltage and currents To obtain positive rotation data exchange Torque are connected acb with Voltage clip from red to yellow and negative kW respect to electrical exchange CT from red to yellow Keep positive pf hardware Displays that orientation of CT the same positive the VFD is turning in negative direction motoring Three power CT s are Turn the three CT s around Reverse direction factors Facing the wrong of arrow Details direction or Exchange cyclical locations of CT s red to Power are Connected to the yellow yellow to blue blue to red If results negative or wrong phase still not correct perform this step one more load is very time Otherwise check a wrong FAR too high or 2 24 2010 71 005 V2 EN a7 EXP4000 VFD sosftware overview FAR too low fo Connected to a Everything Is fine Speed generator and not to Turn the CT s around Reverse direction of negative a motor arrow Torque CT s polarity is positive or wrongly connected vice versa Phasors In VFD mode instantaneous current phasor versus the instantaneous voltage phasor is shown Zoom Info bree i i 7 Mvp fasso ess We 267 2 ET ala Jezo far mib fase 274 ile e52 fi53a 571 500 400 300 200 100 gt 100 300 400
153. ver this manual includes special safety precautions applicable to the use of the EXP4000 NOTICE The maximum rating of the EXP4000 is 1 000 V 500 V for DC operation 1 000 V 500 V DC operation is the maximum allowable voltage between any two of the four voltages and the ground clip Under no circumstances connect the voltage sensing circuit to higher voltage levels Doing so will cause severe damage to instrument Operational safety warnings Baker Instrument Company an SKF Group Company recommends that the operator comply with the following safety precautions 1 2 Comply with all your facility s safety practices at all times Ensure physical setup does not interfere with your facility s current or intended operation Additionally these safety precautions must be followed otherwise dangerous shock hazards may exist 1 Use whatever safety equipment required by your organization including eye protection high voltage gloves arc flash rated masks hoods and any required PPC Prior to opening any MCC Motor Control Cabinet ensure that appropriate arc flash protection clothing is worn 2 Ensure that appropriate lockout tag out procedures are properly understood and Implemented by all personnel 3 Every connection at MCC must be done while rotating system is powered down 4 Depending on the kind of test to be run ensure no physical proximity to the shaft of the motor or any other moving part of the machinery 5 Do n
154. w adjustments within the Options menu dropdown Override speed If the speed is wrong it can be overridden Click Options the override speed Move the toggle arrow to the on position and then input the appropriate speed gt Override Speed Estimate X Override Speed A r 1800 00 RPM On i OK Cancel Fig 10 3 Override speed Adjust electrical acquisition time This will affect absolute test time and increase rotor bar test resolution lf rotor bar problems are suspected it can be helpful to increase the acquisition time to obtain more data iy Electrical Acquistion Options x Electrical Acquistion Time sec Fig 10 4 Electrical acquisition options 2 24 2010 71 005 V2 EN 118 EXP4000 Example test and report generation Spectrum acquisition options This adjustment allows the user to change the frequency range being monitored along with the resolution This affects the voltage current and the torque spectrums IT spectrum Acquistion Options A preeseessseseseseesecesesseeossesseessessseesseseeeg I More FMAX Hz 500 00 5000 00 10000 00 15000 00 20000 00 25000 00 3000 00 Lines of Resolution 2048 Frequency Resolution 0 183 Fig 10 5 Spectrum acquisition options Looped acquisition Timed acquisition In the tools menu there are two types of acquisition modes Either looped or timed The continuous looped acquisition mode ensures the user of some piece of mind in gathering
155. y precautions applicable to the use of the EXP4000 13 NOTICE The maximum rating of the EXP4000 is 600 V 500 V for DC operation 600 V 500 V DC operation is the maximum allowable voltage between any two of the four voltages and the ground clip Under no circumstances connected the voltage sensing circuit to higher voltage levels this will cause severe damage to instrument 14 NOTICE The maximum voltage rating of the EXP4000 DC current meters is 600 V Under no circumstances connect the current sensors to circuits of any higher voltage this will cause sever damage to instrument Operational safety warnings Baker Instrument Company an SKF Group Company recommends the following safety precautions 5 Comply with all your facility s safety practices at all times 6 Ensure physical setup does not interfere with your facility s current or intended operation Additionally these safety precautions must be followed otherwise dangerous shock hazards may exist 2 24 2010 71 005 V2 EN 116 EXP4000 Example test and report generation 25 Use whatever safety equipment required by your organization including eye protection high voltage gloves arc flash rated masks hoods and any required PPC Prior to opening any MCC Motor Control Cabinet ensure that appropriate arc flash protection clothing is worn 26 Ensure that appropriate lockout tag out procedures are properly understood and implemented by all personnel 27 Every conn

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