© 2008 Eaton Corporation. All rights reserved.

“5 Ways to Protect your Motor and Increase your Uptime with Solid-State Overload Relays”

-hosted by Erie Bearings

Adam Krug – Product Manager Industrial Controls Division, Eaton Corporation

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Training Goals• Understanding of basic motor protection then and

now

• “5 Ways to Protect Your Motor”• Leveraging additional capabilities from electronic relays beyond

simple thermal protection to protect motors

• “Protecting your Utility bill”• Getting onboard the energy monitoring trend with today's relays

• “Protecting your load/pump”• Seeing beyond the motor to the actual load with no additional

hardware

3 3

Traditional Motor Protection Overview

• Traditional OLR’s monitor 3-phase current to simulate motor winding temperatures

• OLR relay opens up contactor and prevents motor insulation breakdown

• Technology used – Thermal expansion properties of bi-metal cause trip

Contactor

Breaker/Fuses

Overload

Relay

Motor

XT • Thermal•0.1 - 630A

Freedom C306• Thermal• 0.25 - 1500A

IEC Style

Starter NEMA Style

Starter

4 4

Bi-Metal Technology Overview

• User selects “Heater Packs” by motor nameplate FLA (Full Load Amps)

• User selects singular overload trip class (either 20,10 by purchasing specific heater pack

Drawbacks• Very limited adjustability of FLA

range 1.6:1 – Why?• Thermal properties of metal

• Inconsistencies in trip times – Why?

• 10-15% variation in trip times• Manufacturing of metal

compositions

5 5

Solid-State Technology Overview

Benefits:

• No “Heater Packs”

• Settable Trip Class (5,10,20,30)

• Very wide adjustability of FLA range – Why?

• Flexibility of electronic design

• Large reduction of part numbers

• More motor protection onboard

• More consistent protection

• Energy cost avoidance

• Pump and Load Protection

C440• Electronic• 0.3 - 1500A• Communicating• Ground Fault

C441 Motor Insight• Energy Monitoring• Motor and Pump Protection• Advanced Diagnostics• 1 - 540A

6 6

C440 Protects & Monitors Motors w/ Fewer Part #’s

0.33 1.65

1 5

4 20

20 100

35 175

60 300

120 600

200 1000

300 1500

9 45

CT Ranges

Q1

2011

• 5 part numbers (excluding CTs) for 0.33-1500 amps!

• 0-690 Vac

7 7

C441 Protects & Monitors Motors w/ Fewer Part #’s

1 9

60 135

120 270

FLA Ranges w/CTs

240 540

• Motor coverage from 1-540 amps with only 2 part numbers

• 0-660 Vac

5 90

8 8

210 Thermal Overload Relays

5 Eaton Electronic Overload Relaysor

Which has more capability?

Comparison to the Equivalent Bi-Metal Relays

9 9

Training Goals• Understanding of basic motor protection then and now

• “5 Ways to Protect Your Motor”• Leveraging additional capabilities from electronic relays

beyond simple thermal protection to protect motors

• “Protecting your Utility bill”• Getting onboard the energy monitoring trend with today's

relays

• “Protecting your load/pump”• Seeing beyond the motor to the actual load with no additional

hardware

10 10

C440 and C441 Overload Relay Value • Advanced warning/protection and location of a pending motor/load failure

• Improves process uptime and throughput

• Reduces costs per repair

• Reduces capital expenditures through extension of life

• Optimizes labor- “Finding the needle in the haystack” (which motors get serviced during shutdown)

• Sensorless, non-intrusive, starter-based technology (you need one anyway!)• Cost-effective (versus sensors, wiring, man-hours for install and data interpretation)

• Greater motor coverage

• No firewall to penetrate, since there is no data interpretation needed

catastrophic Protection decreases

maintenance cost per repair and extended

downtime

Deg

ree

of/#

of

failu

res

time

minor

Advanced warning and minor repair extends equipment life

and reduces capital expenditure

Monitoring = Scheduled

Downtime & Energy Cost Avoidance

$

$Accurate

Diagnostics decreases length of downtime and

repeat faults

11 11

Protection Feature Bi-Metal Overload Eaton’s C440 and C441

1. Thermal Overload • Not very accurate

• Relies on thermal characteristics of metals

• Different heater elements for Class 10 or 20

• Accurate, Reliable – electronic design

• Microprocessor based trip time calculations utilize thermal memory tables

• Selectable trip classes (5 - 30)

2. Ground Fault • Does not protect against ground fault • Integral design – no external CT or module

• Selectable (ON/OFF)

Solid State vs Bi-Metal OL: Thermal & GF Protection

2. Ground Fault• Definition:

• A line to ground leakage path from the motor to the ground

• Result:• An undetected Ground Fault can burn through multiple insulation

windings ultimately leading to motor failure

12 12

Protection Feature Bi-Metal Overload Eaton’s C440 and C441

3. Phase Loss • Does not protect against phase loss • Programmable Phase Loss and Phase Imbalance

• Takes starter off-line in 1-20 seconds

• Selectable (ON/OFF)4. Phase Unbalance (current)

• Does not protect against phase unbalance

• Eaton’s C306 bi-metal provides protection against phase unbalance, but may take up to 2 hrs.

Solid State vs Thermal OL: Phase Protection

3. Phase Loss - Current (single-phasing)• Definition:

• One of the three phase voltages is not present

• Source: • Loose wire, improper wiring, grounded phase,

open fuse, etc.

• Result:• Single-phasing can lead to unwanted motor

vibrations causing mechanical wear• Reducing the life of your motor from the extra

heat on the other two phases

13 13

5. Jam• Definition:

• Jam is a current draw on the motor above normal operating conditions, often referred to as locked rotor current. During initial start-up this is referred to as Stall.

• Source: • Mechanical stall, interference, jam, or seizure of the motor or motor load

• Result:• To drive the additional load the motor draws an abnormal amount of

current, which can lead to insulation breakdown and motor failure• Mechanical failure of devices that are jammed caused by the extra

torque of the motor.

Protection Feature

Bi-Metal Overload Eaton’s C441

5. Jam/Stall • Does not provide Jam Protection • Programmable Jam and Stall Protection from 100%-400% of FLA

•Same setting can be used down to 50% of FLA for current alarming

6. Overcurrent & current level alarming

• Does not provide Overcurrent

Solid State vs Thermal OL: Jam/Stall/Overcurrent

14 14

7. Phase Rotation (phase-reversal)• Definition:

• Improper wiring leading to phases being connected to the motor improperly causing the motor and load to spin the wrong direction

• Source: • A mis-wired motor

• Inadvertent phase-reversal by the utility

• Result:• Phase-reversal can cause unwanted directional rotation of a

motor

• Possible mechanical failure and/or injury to an operator

• You wouldn’t drive your car and then throw it in reverse at 60 mph would you?

Protection Feature

Bi-Metal Overload Eaton’s C441

7. Phase Reversal • Does not protect against reversal of phase • Programmable Phase Reversal Protection

•ABC, ACB or OFF

Solid State vs Thermal OL: Phase Reversal

15 15

Under voltage• Definition:

• When the line voltage to the motor is below the specified rating

• Source: • Poor line quality

• Result:• motor stall • spinning the motor too slowly which effects throughput• excessive current draw. This increases the heating of the motor windings

and can shorten insulation life. • A trip limit set to 90% of rated voltage is recommended by NEMA.

Protection Feature

Bi-Metal Overload Eaton’s C441

8. Under Voltage

9. Over Voltage

• Does not protect against under or over voltage

• Does not protect against voltage at all

• Fully programmable over and under voltage protection

• Alarm and Trip modes

• Auto resets when voltage is good

Solid State vs Thermal OL: Line Quality Protection

16 16

Training Goals• Understanding of basic motor protection then and now

• “5 Ways to Protect Your Motor”• Leveraging additional capabilities from electronic relays

beyond simple thermal protection to protect motors

• “Protecting your Utility bill”• Getting onboard the energy monitoring trend with today's

relays

• “Protecting your load/pump”• Seeing beyond the motor to the actual load with no additional

hardware

17 17

Annual U.S. Savings Potential from Continuous Monitoring for Energy Efficiency and Reliability

$-

$1,000,000,000

$2,000,000,000

$3,000,000,000

$4,000,000,000

$5,000,000,000

$6,000,000,000

$7,000,000,000

Pump Compressor HVAC (Fansand

Refrigeration)

Conveyor Other (materialprocessing,

….)

Revenue Impact ($$)

Energy Cost Savings ($$)

Maintenance Cost Savings ($$)

Energy Monitoring

• Customers could realize an estimated $23B savings (U.S.)

Sources: DOE 2002 Industrial Electric Motor Systems Market Opportunity Assessment, US Dept of Commerce 2002 Census, Team analysis

$5B

$3.6B

$6.2B

$2.3B

$6.1B

18 18

• In the U.S. motors use 71% of the electrical energy in a typical industrial facility

• Large population of motors in the 20-300 hp range consuming the majority of energy

• Very little monitoring done on low horsepower motors <1%

Energy Savings

Motor System Energy Use (GWh/YR)

-

10,000.00

20,000.00

30,000.00

40,000.00

50,000.00

60,000.00

70,000.00

1-5 6-20 21-50 51-100 101-200 201-500 501-1000 1000+

Compressor

Pump

Fan

19 19

Eaton’s C441 Monitors (data/warning)

• Current Per Phase and Average RMS

• Current Unbalance Percent*

• Ground Fault Current*

• Voltage Per Phase and Average RMS

• Voltage Unbalance Percent*

• Power

• Power Factor• Frequency*

• Motor Run Hours*

• Thermal Capacity

C441 Motor Insight Monitors Power

•Avoid peak demand charges

•Shed non-vital loads

•Identify and rectify increased consumption

•Identify discrepancy between equal loads

•Identify Power Factor line Items

20 20

Motor Insight Success – Energy Savings May 2009 Control Engineering, Sheboygan WWTP

Scenario:

• Three 480V 75 hp, 96 amp tripping-current motors at Indiana Ave lift station

• Customer was previously only monitoring flow to detect problems

• Flow was the same for all three pumps, however with Motor Insight they observed pump 3 drawing abnormal power due to a foreign object on the impeller

Motor 1

50 KW

Motor 2

50 KW

Motor 3

75 KW

Motor Insight - Value Add:

ENERGY SAVINGS• Observed this abnormal operation

in real-time

• Sent maintenance personnel immediately upon observation and removed the foreign object

25 KW *12 hours * 365 days *$0.10/kw-hr= $10,655 of wasted energy

21 21

Monitoring Beyond EnergyC440/XTOE

• Current per phase &

• Average 3-Phase RMS

• Current Unbalance percent

• GF current

• Thermal Capacity

• Motor state status

• Last fault

• Frequency

C441 Motor Insight• Current Per Phase &

• Average 3-Phase RMS

• Current Unbalance Percent

• GF current

• Thermal Capacity

• Motor State Status

• Last 10faults

• Frequency

• Voltage Per Phase and Average RMS

• Voltage Unbalance Percent

• Power

• Power Factor

• Motor Run Hours

• Motor Starts Count

22 22

C440 and C441 Overload Relay Value • Advanced warning/protection and location of a pending motor/load failure

• Improves process uptime and throughput

• Reduces costs per repair

• Reduces capital expenditures through extension of life

• Optimizes labor- “Finding the needle in the haystack” (which motors get serviced during shutdown)

• Sensorless, non-intrusive, starter-based technology (you need one anyway!)• Cost-effective (versus sensors, wiring, man-hours for install and data interpretation)

• Greater motor coverage

• No firewall to penetrate, since there is no data interpretation needed

catastrophic Protection decreases

maintenance cost per repair and extended

downtime

Deg

ree

of/#

of

failu

res

time

minor

Advanced warning and minor repair extends equipment life

and reduces capital expenditure

Monitoring = Scheduled Downtime

Energy Cost Avoidance

$

$Accurate

Diagnostics decreases length of downtime and

repeat faults

23 23

Monitoring Data for Action

• Modbus, DevicNet, Profibus easily ties OLRs into Plant Management Systems

• Schedule Maintenance when changes are detected before downtime occurs

• Line Quality, Pump behavior, Thermal Capacity, Consumption

• Find the needle in the haystack and change routine spot checks into targeted maintenance

•

24 24

Monitoring Benefit – Doing More with Less Cleveland Based Steel Manufacturer

Scenario

• 3 Hot Well Pumps (480VAC 150HP), two of them are needed to run all of time and the other is hot spare.

• 3 Cold Well Pumps (480VAC 300HP), two of them are needed to run all of time and the other is hot spare.

• 2 Panel Pumps (480VAC 300HP), one of them is needed to run all of time and the other is hot spare.

• 2 Lance Pumps (480VAC 150HP), one of them is needed to run all of time and the other is hot spare.

• “We put Motor insight on each pump. We have designed a screen that shows each motor data live. We can check the pump operation from any PC in plant. I can also use eworkplace from home and check the status of each pump from my couch. We trend all data collected, and have a goal of using this to detect/predict motor failure. With all this data, we can also automatically switch over to the spare before or immediately after a failure. With the hot and cold well pumps, we have to have the same number of pumps running at the same time or there is an immediate flood in the basement.”

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Training Goals• Understanding of basic motor protection then and now

• “5 Ways to Protect Your Motor”• Leveraging additional capabilities from electronic relays

beyond simple thermal protection to protect motors

• “Protecting your Utility bill”• Getting onboard the energy monitoring trend with today's

relays

• “Protecting your load/pump”• Seeing beyond the motor to the actual load with no

additional hardware

26 26

Critical Pumps at Various Horsepower

Source: Eaton Survey in Motor Diagnostics and Motor Health News

27 27

Power-based Overload Relays can “See” the Load beyond the Motor

• C441 MI looks at 3 phase current and 3 phase voltage & calculates power

• kW based OLR allows for monitoring of load performance

• kW based OLR allows for protection of harmful conditions to loads (pumps)

Contactor

Breaker/Fuses

Overload

Relay

Motor Load

28 28

Load Protection

Low Power• Definition:

• Power provided to the motor falls below normal operating conditions

• Source: • A portion of the user's load disappears, changed in viscosity, hydraulic fluid leakage, reduction in feed-rate,

broken belt, a dry-pump (low suction head), or a dead-headed centrifugal pump.

• Result:• Mechanical failure can or has occurred

• Running a pump dry or running a pump in a dead-headed condition can cause excessive heating, damaging expensive seals and breaking down desired fluid properties

Protection Feature

Bi-Metal Overload Eaton’s C441

10. Low Power

11. High Power

• Does not protect against under or over voltage

• Does not protect against voltage at all

• Fully programmable over and under voltage protection

• Alarm and Trip modes

• Auto resets when voltage is good

29 29

• Open valve = not dead-headed

• Good pump state, because the fluid in the centrifugal pump is constantly flowing keeping the pump cool

• In this state Motor Insight would read nominal power (KW) draw

Outlet Valve

C441 Pump Protection

30 30

• Closed inlet valve = Low suction head or dry pump.

• This can be caused by a closed valve as shown here, or a unnatural clog from foreign material

A low suction head situation creates a low power draw on the motor. Motor Insight detects the low power draw and trips the motor to protect the pump

Inlet Valve

Outlet Valve

How Motor Insight Protects a Low Suction Head/Starved Centrifugal Pump

31 31

• Closed blocked valve/dead-headed = bad pump state Outlet

Valve

A dead-head situation creates a low power draw on the motor. Motor Insight detects the low power draw and trips the motor to protect the pump saving your seals, downtime and maintenance costs

C441 Motor Insight Protects a Dead-headed Pump

32 32

What did we learn?

• More than “5 ways” to protect your motor and process• Thermal, GF, Phase loss, Phase Imbalance, Jam, Stall, Current level alarms, Phase Reversal, Under

Voltage, Over Voltage, etc.

• Advanced Motor Protection • Improves process uptime and throughput• Reduces costs per repair • Reduces capital expenditures through extension of life• Optimizes labor- “Finding the needle in the haystack” (which motors get serviced during shutdown)

• “Protecting your Utility bill”• Avoid unnecessary energy costs• Shed non-vital loads• Identify and rectify increased consumption overtime• Identify discrepancy between equal loads• Identify Power Factor Line Items

• Other Benefits of Monitoring• Early detection of failures

• “Protecting your load/pump”• Pump failures from deadhead and dry conditions • Submersible pump/motor failure from poor line conditions• Detect improper feed-rates• Detect improper viscosities• Find broken shafts/belts• Leakage of hydraulic lines

33 33

XT SmartWire•Communicating• 0.3 - 65A

2010

Motor Protection Relay Value Map to Process Uptime, Energy Savings, & Diagnostics

Per

form

ance

Price

Current product GAP, Electronic Overload

with Ground Fault and Communications

Overload Relays

XT • Thermal•0.1 - 630A

XT XTPR•Thermal• 0.1 - 65A

XT PKE•Electronic• 0.3 - 65A

2011

Motor Insight• Energy Monitoring• Motor and Pump Protection• Advanced Diagnostics• 1 - 540A

2010

Manual Motor P

rotectorsC440• Electronic• 0.3 - 1500A

2010

C440• Electronic• 0.3 - 1500A• Communicating• Ground Fault

2010

Freedom C306• Thermal• 0.25 - 1500A

2009

© 2008 Eaton Corporation. All rights reserved.

“5 Ways to Protect your Motor and Increase your Uptime with Solid-State Overload Relays”

hosted by Erie Bearings

Adam Krug – Product Manager Industrial Controls Division, Eaton Corporation

Thanks for Participating in the Webinar!

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