I

MOTOR CURRENT ANALYSIS DEB AGENCIES

IIOT BASED SENSOR FOR CONTINOUS MONITORING OF CURRENT AND VOLTAGE WHILE INDICATING ALL
MECHANICAL AND ELECTRICAL FAULTS IN THE MOTOR
Motor Condition Monitoring Without Sensors
A New Approach in Predictive Maintenance
iiot based sensor
The Motor iiot based sensor is a powerful online condition monitoring, predictive maintenance
and power meter tool intended for critical AC rotating equipment. The patented mac hi ne learning
algorithm of iiot based sensor enables comprehensive fault detection up to 6 months in advance.
With arou nd the clock monitoring and real-time model-based voltage a nd current analysis, iiot
based sensor can detect electrical, m ech anic al as well as process fauIts of fixed, variable speed m o to rs
a n d generators w h i l e provid!ng all the benefits without the hi g h complication and cost of traditional
systems.

Motor e MCM monitors the condition of equipment driven by an electric motor, effectively using
the motor itself as a sopnisticated transducer. It requires only connection into the motor's electrical
supply, avoiding the need or specialised sensors. Because Motor iiot based sensor is permanently
installed, it provides continuous fault monitoring and does not depend on expensive manual oata
collection.
Motor Condition Monitoring System
iiot based sensor

The patented NASA-deve loped technology provides macnine lea rning capability in a com pact,
affo rdable, panel-mountea instrument. iiot based sensor can detect wide variety of fauIts by
automatically teaching itself about the normal operatio n environment of your equ ipment so tnat it
can accurately identify and diagnose faults Iong before they become a th reat.

Online Condition Monitor ing

Automated Fault Early Fault Detection

Diagnosis

Remote Monitoring Comprehensive FauIt

Coverage

Only Viable Solution For Energy EIf iciency Effects

Hard To Reach Motors Of Faults

Avva rd W i n n i n g Online Power

Technology Monitoring
• Decrease on maintenance cost • Oil & Cas « Compressors
• Productiv1 Increase • Ener9y « Fans
• Equipment life extension • Cement • Pumps
• Energy saving • Metal • Conveyors
• Improved process safety • PWrrnaceutical • Generators
• Automotive » Motor Driven Equipment
• Water • AHU
• Transportation • Mixer
• Food 8 Beverages
• Builoings

Wa tc h e - M C M vi d eo
 Continuous Monitoring of
Your Rotating Equipment

iiot based sensor monitors your rotating equipment continuously, constantly taking
measurements and comparing them with the digital twin it created during the self-learning process.
Unlike conventional online systems, its unique machine learning algorithm allows it to recognise
normal operation in a wide range of conditions, sucn as different speeds or loads —allowing tig ht control
without false alarms. If iiot based sensor identifies a new operating state not experienced during the
self-learning phase, it gives you the option of including this state in all future monitoring.

a Fault Coverage Process faults Power Monitoring

. L o o s e foundation/ . Hig h energy consum ption . Vr, Vs and Vt
com po nents . Low efficiency . Ir, Is and It
. Mechanical . Cavitation in pu m p s . Frequency
u n b a l a n c e/ m i s s a lig n m e n t . Flow turbulence in fans, . Voltage Unbalance
. Transmission faults blowers . Current Unbalance
. Driven e q u i p m e n t faults . Filter and neat . Motor Load
. Gearbox, belt, cou pling exchanger fouling . Power Factor
. Bear ing . Lubrication . Active Power
. Stator and rotor faults . Oversize/undersize . Reactive Power
. Internal electrical fauIts motors
. Total and odd
. External electrical faults . Air how disturbance
harmonics
How Does It Work?

Motor iiot based sensor uses a mathematical displacements resulting from an imbalance in a
modelling technique to detect and diagnose driven fan are transmitted through the coupling
faults in electric motors and connected to the motor, changing its e(ectricaI
equipment. The mathematical model, which characteristics in a measurable and repeatable
consists of a set
differential of
equations representing the way. This allows Motor iiot based sensor to use
electromechanical properties of the system, is the motor as a sensor that can detect faults in
built up during the self-learning phase of the motor, drive train and the driven
operation. During this phase, the three input equipment. When monitoring, Motor iiot
voltages and three output currents are based sensor continuously compares model
continuously measured and processed using parameters with those held in the reference
system identification algorithms which model created during the self-training
determine the model parameters under a full phase. By matching changes in each of these
range of operating states. Once complete, Motor parameters against the equivalent physical
iiot based sensor has a complete model characteristic of the motor or driven system
representing normal behaviour of the machinery and assessing the severity of the change, Motor
in a full range of operating states. When a iiot based sensor determines whether the
fault starts to develop in the motor, drive present condition of the equipment is normal,
train or the driven equipment, this has an and if not what action should be taken. This
effect on the output current waveform, approach not only allows m uch more sensitive
making the real system behave differently and reliable alerting than is possible with
fexample, smallsystem,
r o m t he model radial
For and torsional
displacements resuIting f r o m a n imbalance in a
conventional level-alarms, but also recognises
the type of defect causing the problem.

Mesaurement Current

Real Equipment

Calculated Current

Digital Twin (iiot

based sensor)
It Simply Works
iiot based sensor provides clear information for fault detection, diagnostics, time to failure and
corrective actions. It only demands your attention when it detects a problem. This makes it very
attractive in comparison with walkaround systems which require considerable effort and cost just
to find out whether you have a problem or not. It automatically assesses the severity of any
variations from normal operation and presents the results of its sophisticated analysis to the
user in a simple, compelling traffic light display. As a fault starts to progress, the traffic light
changes from green to orange, indicating that maintenance action will be required in the future. A
red traffic light indicates that the high severity of the problem requires immediate attention.

Motor Enterprise Software

Motor IoT Software

Permanently installed Software provides processed data results in an actionable form which greatly
reduces the specialist diagnostic skills required of the user, m a k i n g th e b en efi ts of condition
monitoring ava ila ble to m any groups who have considered it too difficult in t h e past.
Monitoring Software

e. MCM system offers various remote monitoring options ranging from local to cloud based IoT
monitoring.

« AES Softvva re (Windows based) run ning on local server

• Motor Web IoT Platfo rm on cloud server
› 3rd party m o n i to rin g software integration via OPC

Pum ps Fans Conveyor Ch iller Mixer Ah u Compressor Generator

• Simple interface providing actionable informatio n via automated fauIt diagnosis capability
• Com pherensive fauIt coverage by monitoring eIectricaI,mechanicaI and process conditions of
rotating equipment
• On remote or inaccessible equipment vvhich is difficuIt to monitor with other technologies
In hazardous or extreme environments where sensors cannot be mounted to the equipment
• Integration packages a re avail able to a wi d e range of 3rd party systems, including Integrated
Condition Monitoring, SCADA/HM I, and Reporting/Business Intelligence
 Advanced Fault Diagnosis and Alarm Types

Conventional condition monitoring systems are great at collecting data, but require a lot of expertise to
turn it into actionable information —just the part you really need. Motor iiot based sensor is able to
use its knowledge of your machinery built up during the self-learning process not just to detect when
a fault is developing but also to recognise the type of fault. This allows your maintenance team to
focus their efforts in exactly right area, without relying on the presence of a diagnostics expert. The
diagnostic system is able to identify most of the common mechanical faults associated with
typical electric motor-driven equipment, from unbalance and misalignment to bearing problems.
Additionally, since Motor iiot based sensor works by measuring the current and voltage taken by the
electric motor it can also diagnose problems with the electric motor, as well as giving an insight into
the process conditions and the potential to optimise them on the basis of power, phase angle and total
harmonic distortion.

EQUIPMENT STATUS REPORT

Normal
.y Watch Line *
€ Watch Load
Input
‘°” n
Exa m i n e 1 t
Examine 2 *
Advanced Analysis Tools for Experts

The Motor iiot based sensor .software allows users detailed analysis with Power Spectral Density
and Trend Analysis tools for root causes of”the f a u l t

iiot based sensor is specifically designed to be.self-sufficient, only requiring your intervention when it
detects a problem. It can also act as an intelligent component o.f a complete, plant-wide
monitoring and diagnosis system. You can connect it into. your own .systems using its standard
interfaces, all.owing results to be presented to your staff through existing display Systems Motor can
supply MCMScada software to collect and manage information from .all your Motor MCM units,
provide enhanced diagnostic capability, and to allow remote operation of the complete System.
This can also a l l w Motor to help out with your condition monitoring program by providing
remote advanced interpretation services.

Tfend Sc een

. Multi Ian”guage support • OPC DA support

. Advanced trending tools. • Power spectral density.analysis
Ma.il tool for cI!iagnostic alerts • 6 cha'nneIs waveform capture feat.ure
Only Viable Solution for Hard-to-Reach
Equipment With EPorless Installation

Installing Motor iiot based sensor is a sim ple matter of connecting it to the three supply phases of the
motor using current (and sometimes voltage) transformers and mounting the monitor in any
convenient panel. Motor iiot based sensor is typically located in or near the motor control centre,
making especia Ily valuable in situations where the plant is not easily accessible, either because it is
remote or because the local environment is hazardous or inhospitable. This approach gives you all
the advantages of using online systems without the high cost of running cables to sensors
mounted on the machine itself. When you first switch it on, iiot based sensor begins an automatic
self-learning process during which it learns the normal operating condition of your equipment. At the
end of this short training period it's ready to start monitoring, without forcing you to go through
lengthy manual setups.
Motor Condition Monitoring System
iiot based sensor

No Name Function
1 Supply voltage terminal Terminal for operational power (AC10O-24OV)
Empty terminal No function
3 Mator voltage input Terminal for motor input voltage
Status LED Indicates Power status, Module status, etc.
5 CT connection port Terminal for 3 phase CT connection (RU)
ZCT connection port Terminal for ground CT connection
Reset button Trip Relay Reset Button
8 RS-485 terminal Termina! for RS-485 communication
9 Empty terminal No function
lO HMI terminal Terminal for connecting with HMI (R345)
Ethernet port Terminal for ethernet communication (R345)

Motor fault diagnosis + Power Monitoring • RS4B5 serial communication and Erhernet
Predictive diagnosis of Electrical and Mechanical Faults communication support
• (3-phase AC motor) Energy meter function › EN 60255-26:20ï3, EN 6l0ï0-12010, EN6I326-I: 2006
. Measuring types THD, Current/ Voltage Unbalance, • Compact size (94x63x100 mm)
Active/Reactive Power • DIN rail and wall mount available
Support Panel display monitor (4J “TFT LCD monitor)
iiot based sensor
Communication Diagram

LAN Communication Diagram

switch hub

TCPIIP !

TCPIIP
iiot based sensor
MV/HV Installation

MV/HV - LINE lnsta‹1at\on (3CT}

motor Voltage > 69DV (L-Lj

HV - MNE Installation {2CT}

Motor Voltage • 69OV (L•L)
iiot based
sensor
LV Installation

LV - LINE Installation Motor Voltage <

69OV (L-L)
SA < Motor Current <2000A
CT:5A-20O0A

LV - ino installation lvtotor Voltage <

69OV (L-L)
5A • Motor Current <2OODA
CT:SA-2OO0A
iiot based sensor Touch Panel Screen

Panel Display Monitor with 4.3" TFT LCD

. Used as field monitoring

. On-site power monitoring
lY û . Clea r display w i t h 4.3" TFT LCD
!2.5 . PIug and play with iiot based sensor
’'"',.- device wit hout exta rnal power supply
. Possible to change the setting of the
device in the field
. Easy operation wi t h large touch keys
Terminal Description

. LCD screen 4C“ TFT Color LCD

. Status LED Indication of operation status
. Six keys are used to select display and set
• Installation Clip The clips are used for fixing
the HMI to the panel
. Communication terminal to iiot based
sensor Device

Dimensions

a Cut Out
o6s mm

120
90

•Step1 •sopZ
Panel Cutting Put the HMI into the panel

Connect with iiot based sensor

Cable with R34S

jack for HMI
iiot based sensor Datasheet
Rated Specifications
General Information
3-phase, AC motors & generator. Motor current (load) variation must be less than
Motor Type 4596 during 6 sec clata acquisition period. DOL, Star-Delta, Soft Starter, Variable
Frequencyoriver

Ambient Conditions
Operating Temperature lO -5O°C
LI II @i t$’ P•80, Relative Hum idity, non-condensing
Pollution D e g r e e

Altitude 20O0m(6562fi)
lPRating ID40

Rated Voltage lOO-Z4OVac

Allowable Input Voltage
Frequency
Power Consumption
Qver Voltage Category
Measurement Voltage Inputs
Measurement Current lnpMs
Frequency Range
Communication
Network
90% - JJ0% (of rated voltage)
50/6OHz
IEC6lOl0 Cat iit
max 690Vac (Line to Line)
Up to 25OOA with three Cat III Current Transformers: O.5% accuracy
15-110Hz
RS48S Mosbus- RTU fOnly for power monitoring) | TCP/IP Modbus TCP

43" LED Displays electrical measurement, failure information, and setting values
Status LEDs Displays power status, module status, comm status, alarm for diagnosis
Di p e n s i o n s WxHx L 12O mm x lO5 m rr\ x 15 m m

Physical
Weight 450d )lbl
D! mensions WxHx L 96mmx64mmxllOmrn
Mounti ng FontPanelMounting(indoor)
compliance & Certifications
EMC EMC Directive 2004flO8/EC, EN6326-1, IEC6J326—l
EectricaSaetyDirective2OOW9iEC,
Safety
EN61Ol01JEC6l0)0-l
Measurement Functions
Voltage. 3 p ha s e vołtagø [line-line), u n b a l ä n œ [%]
Current 3 p h a s e c u r r e n t a n d lea k a ge c u rrent, u n b a l a n œ [96}, THD {9s)
active Power Measuring active power'[kWJ
ReactIvë’Power Meäsøring roaütîvã. povvet [kVAr}
Frequency Measurìng Frequency [Hz]
Powe.r factor kłeãsunng Power factor
Energy Total Whr, Today Whr, Prev day Whr
Dața an”d Time Year, monțh, dąy, hour, mÏnute, second

Auxil'iary Fúrictions
Password Pæsword Secure.confÏğurażłon.
Communication Serial/Ethernet communicañon for monitoring.status.and event. hisœry
Total Running-Hour Record of total running from installation which earimot:be modified or clœred
Alarm Output älärm signal to 3.out’ğut rëlays
Fault History 3O[d\agrłÖŠÎS} faUlt hÎ5tÖry tÖ the flăs h’ rNe r rłÖ rx

I-imitation OfAuto Reset Attempt Block euto-reset if the:reset count excœds the pre-set count within 30 minutes
Date/Time Information Setting. Save.dàteAİme to provide.exàct time of motor failure.

Motor Condition Monitor and Diagnostic Functions

Status
.OK Motor and dCłven.system.is.wor.kin§ ăs.exğected.
Watch Une Is usually temporary In nature änd..generalİy Ğe. urer does not need
to täXe any.action. However, it lś re'cornmended that when tńls status levël occurs;
the usørsheuld.at I.east assees żhe extent of the change in:tha Ilne›condItlong..as
šigńïficarit chanoës íń the ílnë voltages anó currents rńay be danseróus to the
batch Linë motor. If the Iìna.status change is pe/rsíctent,the user śhoüld assess the root cause
ôfthls.chanğ'e. För'lnstance, It may bë dúe”to a problem in the contactorá or for
Inverter drlvsn motors.the.sëdTngsofthe Inverter may hams bean changed. In any
case, If th:a root.cauæ cannot be remedied easily and quickly.and the. new vöhage
supply œńdltion presents n’.ö danger.to.thë motor, the use.r bœ.the option to send
MCM to the UPOATE.mode. Thiświİl alIew' MCM to learn the ńew voltage. supply
coriditlons, aftør which the'status will everitually return țö normal.
If the process load has not been aİæred,.ôeIJberately;.checłs'for leakage, valve & vane
Watch LoaÕ adjustrne.nt, pæssure gaugë faults; manometër,.dirty fllters (fans, compressors).
If the process.is aKered dëllberatëly, devlce shoulÕ be updatecL
Examine 1 Plan.Maintenance (First Laveł AJarm):There. ara developing mechanical.and/or
electrical fault(s).
Examine 2 Do Mainïananœ (Second Level Alarm):Thëre are developing mechaniœl ärtd/ør:
e\ectïîcel ’fault(s).
Accessory-Split Core Current Transformers
ACZSR-IO-10OmA -E
ACZSR-20-30DmA -E 3x2OA
ACZ5R-dO-7OOrnA -E 3x3oA
AC25R-do-JoomA -E 5x60A
AC25R-1OOHOOmA-E
ACZSR-200-1OOmA -E 3if2OO4
ACgSR-300-1OOmA - E 3x3O0A
5X6O0A
5x600A
AC51R-800-1OOmA -E 3x8OOA
ACgOR-1000-1OOrnA -E 5x1OO0A
AC8OR-15OD-1OOrnA -E
Splltcote current transformers set. ( DZ5mm ) 10A:1OOmA
| Splltcore current transförmars set, ( D2Smm ) 2OA:1OOmA
I splitcore cutrent transformers set, ( B2Smm ) sOA:1OOmA
Splltcora current trancförmers.set, ( gZ5mm ) 6OA:1OOmA
Splftcore current transformers set, ( DZSmm ) 10OA:ïD0mA
Splltcore current transformors set, ( D25mm ) 2OOA:1OOmA
} Splltcore current transformers set, ( 0Mmm ) 300A1O0mA
| Splltcoro current transförmers set. ( id5lmm ) 40OA:J0omA
Splltcore current transförmers set, ( 05\mm ) 6OOA:100mA
Splltcore current transformers set, ( 05Imm ) 80OA100mA
Splitcoæ cürrent trBricfôrrnars set, ( NBornrn ) JOOOA:1OOmA
splitcore current transfbrmers set. ( Beomrn )15O0A:1OOmA
Splltcore current transformers œz, ( 0l05mm ) 120OA:10OmA
Splîtcore”.current trarislörmers set, ( glD5mm ) ZO0oA:1oomA