3.- c441 motor insight training.pdf

7/25/2019 3.- C441 Motor Insight Training.pdf

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2008 Eaton Corporation. All rights reserved.

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C441 Motor InsightOverload & Monitoring Relay


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Motor Insight (1-540 amps)

Reduccin del costo de mantenimiento con la carga bajo control y diagnsticoespecfico en tiempo real

Rpida configuracin datos de cargas asociadas y datos de proteccin.

Capacidad de monitoreo de corrientes, voltages y potencias.

Mdulos de comunicacin mltiples con disposicin de E / S

Advanced Overloads

Motor Insights


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Performance

Price

Freedom C306Thermal OLR

0.25 - 1500A

C396 - StandardSolid State OLR

0.1 - 1500A

XT

Thermal OLR

IEC only

0.1 - 630A

IT.

Solid-State OLR

Communicating0.25 - 400A

Motor Insight

Advanced Monitoring

Advanced Protection

Communications

1 - 540A FLA, 240-600VAC

Motor Protect ion

Motor, Load, & Lin e Protect ion / Monitor ing

C440

Motor Insights


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8 Unidades Basicas:

(170-264V line power)1-90A sin CTs externos

90-540A con CTs externos

(323-528V line power)1-90A sin CTs externos


89-660V line power)1-90A sin CTs externos


(93.5-132 control power)1-90A sin CTs externos


Modulos de comunicacion:Modbus (con y sin I/O)

DeviceNet con I/O

Profibus con I/OEthernet IP (Mid 2010)

Display remotoType 1, 12 and 3RNEMA 3R

Motor Insights C441

CertificationsUL, CSA, CE, RoHS


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MotorProtection

Thermal Overload (Sob recarga Term ica)

Definition: Sobrecarga trmica es una condicin en la que el consumode corriente de un motor supera el 115% de la corriente nominal decarga para un motor de induccin

Causas: Un suministro a tensin reducida al motor causara que la corriente se

eleve para mantener la potencia necesaria

Aumento de consumo en la carga o torque que esta impulsado por elmotor.

Un mal factor de potencia causara sobre consumo de corriente.

Consecuencias: Aumento en el consumo de corriente, sobrecalentamiento de cables y

ruptura del aislamiento, que puede causar un fallo del sistema. Adems,

un aumento en la corriente puede aumentar el consumo de energaexcesivamente y afectar en la facturacin.

Motor InsightsCapacidad Protectora Trip class 5-30

1-90 amp FLA sin CTs externos (540 amp FLA con CTs externos)

Monitoreo FP y Proteccion de bajo voltage.


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MotorProtection


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MotorProtection

Mechanic al Jam (Salto de Carga)

Definicin: Mechanial Jam es similar a la sobrecarga trmica dado que

es un consumo de corriente en el motor encima de las condiciones

normales de operacin

Causas:

Atasco mecnico, interferencias, bloqueos, o el atoramiento de la carga

del motor o el motor

Consecuencias:

Condiciones anormales de operacin y perdida de aislacion.

Motor InsightsCapacidad Protectora

Proporciona un setting configurable que se activa durante el "estado de

funcionamiento del motor," para evitar disparos inconvenientes

Umbral de disparo 150 a 400% de FLA, o OFF

Retardos configurables de 1-20 segundos


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MotorProtection

Groun d Fault (Falla Tierra)

Definicin: Una linea se fuga a tierra

Causa:

Perdida de aislacion, descargas parciales, una corriente L1 L2 L3 sefuga tierra

Consecuencias:

Una falla a tierra puede conducir a una falla del motor, daos a laintegridad del equipo.


Capacidad de proteccin de falla a tierra hasta 0,15 amperios

En el caso de un GF, Motor Insight puede alarmar o disparar un relalternativa que se puede utilizar para activar el interruptor o encenderuna luz de advertencia

Corriente de falla a tierra tambin puede ser monitoreado en tiempo real

Configurable Trip Delay 1-20 seconds, but based on GF level


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MotorProtectionUnbalanced Phase Curren ts (Desbalance de cor r ientes)

Definicion: Diferencia de la corriente entre las fases en un sistematrifsico

Causa:

Cuando una carga trifsica es alimentado con una lnea de baja calidad,la tensin por fase puede ser desequilibrada causando corrientedesequilibrada

Cuando hay una fuga de corriente de fase a fase

Consecuencias:

Las corrientes desequilibradas pueden conducir a los bobinados delestator del motor que se sobrecarguen, causando un calentamientoexcesivo, la reduccin de la eficiencia del motor y la reduccin de lavida de aislamiento


Ajuste de proteccin de desequilibrio de corriente (de 1 hasta 30.1%, ocomo OFF) y monitoreo en tiempo real

Ajustes de desequilibio de voltages (1.20% en el modo de alarma,1.20% como OFF o en modo de disparo) y monitoreo en tiempo real

Retardo de disparo configurable 1-20 segundos


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MotorProtection

Phase Loss - Curren t (sin gle-phasing ) (Perdida de fase)

Definition: Una de las tres fases se pierde

Source:

Multiple causas: no alambrado, alambrado mal realizo, fase a tierra,

fusible abierto, etc.

Consecuencias: Puede conducir a vibraciones del motor no deseados adems de

provocar fases desequilibradas.


Motor Insight tiene un ajuste de fallo de la proteccin cuando el motor

de arranque vee que una de las fases desciende por debajo de 60% de

las otras dos fases

Retardo de disparo configurable 1-20 segundos


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MotorProtection

Phase Rotation (ph ase-reversal) (Secuenc ia de fases negativa)

Definicion: Cableado incorrecto

Causas:

Motor mal conectado

Alimentacion mal conectada

Resultado: Puede provocar accionamiento del sentido de giro del motor en la

direccion incorrecta

Posible falla mecnica y / o lesiones a un operador

Motor InsightsCapacidad Protectora Ajuste de fallo de proteccin configurable, lo que permite al usuario

definir la secuenciacin en fase destinada a tal aplicacin

Setting 1ABC, Setting 2ACB, OFF

NO TRIP DELAY


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LoadProtection

Undercurrent & Low Power (Baja corr iente y Perdida de

Potencia)

Definicion: Potencia media RMS actual suministrada al motor cae pordebajo de las condiciones normales de funcionamiento

Causa: Una parte de la carga del usuario desaparece, causada por una correa

rota, una bomba en seco (baja carga de succin), o una bomba

centrfuga-fuera. Resultado:

Puede causar un calentamiento excesivo, daos en los sellos y romperlas condiciones normales de operacin deseadas.

Motor InsightsCapacidad Protectora Baja corriente (Ajustable 10-90% de FLA, OFF)

Configurable trip delays 1-60 seconds


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LoadProtection

High Power (A lta Potenc ia)

Definicin: La carga del motor est atrayendo ms potencia de loesperado en condiciones normales de funcionamiento

Resultado:

Si una falla de alta potencia no se detecta puede ser que el resultado

del proceso no cumpla con las especificaciones


La potencia puede ser monitoreada en tiempo real

Configurable trip delay 1-60 seconds


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LineProtection

Over vo ltage (Sob re Voltage)

Definicin: Cuando el voltaje de la lnea al motor excede lo tensin

nominal

Causa:

Mala calidad de la lnea

Resultado: Mal funcionamiento

Se recomienda un lmite de disparo de 110% de la tensin nominal


Over-voltage protective settings, up to maximum range of device Todos los fallos relacionados con overvoltage tienen un modo "alarma

trip"

Configurable delay 1-20 seconds


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LineProtection

Under vo ltage (Bajo Voltage)

Definicion:Cuando el voltaje de la lnea al motor est por debajo de la

tension nominal

Source:

Mala calidad de la linea

Resultado: Consumo de corriente excesivo. Esto aumenta el calentamiento de los

devanados del motor y se puede acortar la vida del aislamiento. Se

recomienda un lmite de disparo establecido en el 90% de la tensin

nominal


Under-voltage protective settings, down to minimum of device range

Todos los fallos relacionados con overvoltage tienen un modo "alarma

trip"

Configurable delay 1-20 seconds


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LineProtection

Unbalanced Voltage (Desbalance de Voltages)

Definicion: Tensin desigual entre las fases en un sistema

trifsico

Causa:

Cuando una carga trifsica es alimentado con una lnea de baja

calidad, la tensin por fase puede ser desequilibrado.. Resultado:

Tensin desequilibrada provoca corrientes de desequilibrio,

que conducen a los bobinados del estator del motor a

sobrecargas, provocando un calentamiento excesivo, reduccin

de la eficiencia del motor y reduccin de la vida de aislamiento Motor InsightsCapacidad Protectora

Voltage Unbalance ajustable 1-20%, OFF

Monitoreo en tiempo real


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Motor Insights

El Motor Insight, el primer producto inteligente dela familia de soluciones de control de energa de

Eaton, es un dispositivo de proteccin del motor,

carga y lnea altamente configurable con

supervisin de la alimentacin, el diagnstico y lascomunicaciones flexibles le permite al cliente

ahorrar energa, optimizar su programa de

mantenimiento, y configuracin de mayor

proteccin del sistema que extiende la vida delequipo, lo que reduce los costos generales y el

tiempo de inactividad


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Motor Insight ExitosAhorro de EnergiaControl Engineering

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 theyobserved pump 3 drawing abnormal current due to a foreign object on theimpeller

Motor 1

Draws 60

amps

Motor 2

Draws 60

amps

Motor 3

Draws 90

amps

Motor Insight - Value Add:

ENERGY SAVINGS Motor Insights advanced

monitoring capability and flexible

communications capability allowed

the plant to observe this abnormal

operation in real-time

They sent maintenance personnel

immediately upon observation and

removed the foreign object

sqrt 3*14.4 kW*$0.10/kW-hr *24 hours/day*7 days/weeks*26 weeks/year

= $10,894 of wasted energy


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Motor Insight ExitosOptimizacion de MantencinControl Engineering

Pre Motor Insight Maintenance Practice:

Limited operational information required weekly inspections of motors and pumps in hard toaccess areas30 FEET DOWN!

Inspection required 2 personnel due to OSHA regulations

Listened to operating noise

No pre-notion of problems that could be occurring, so individual may be over or under-qualified for issue at hand

No pre-notion of problems that could be occurring, so tools at site may be inappropriatethus requiring multiple trips to site

Motor InsightValue Add: MAINTENANCE OPTIMIZATION Eliminating Unnecessary Inspections: Knowledge of real-time data along with 10 history fault-queue enables for

sending personnel only when data from Motor Insight indicates an issue

Optimizing Labor Skill Sets: Understanding of fault-type allows for appropriate maintenance personnel selection.Having the right man for the job enables the plant to better utilize skill sets reducing wage rates per service tripI.e. dont sendyour 40-year maintenance person to clear a clog

Reducing Service Time: Understanding of fault-type allows for proper tool selection before heading to site, avoidingcostly second trips and reducing service time

Pre-Motor Insight:

50 service trips/year * 2 labor heads * $40/hr * 2 hours/service trip = $8,000/yr

Post-Motor Insight:

15 service trips a year * 2 labor heads * $30/hr * 1 hour/service trip = $900/yr


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Motor Insight ExitosAumento Vida Util de EquiposControl Engineering

Scenario 2:

A centrifugal pump is pumping against a mostly closed valve. The pump continues to runbecause the float limit switch is not dropping as the water level is not decreasing. A secondpump is turned on to compensate, thus two pumps are running and are performing the work ofessentially one pump

Pre-Motor Insight:

Both pumps continue to run in parallel wasting valuable energy

Pump 1 is running unnecessarily, since it is doing almost no real work, and thus putting

unneeded hours of operation on the pump and the motor, wearing out bearings The dead-headed pump 1 continues to run and heats-up quickly, heat-aging the pump-seal

thus decreasing the life of the pump

Motor Insight Value - Add: EXTEND EQUIPMENT LIFE & REDUCE DOWNTIME Reduction of wasted run-time hours: Due to the protective-fault feature called Under Power Motor Insight faulted

Motor 1 taking it offline (A centrifugal pump goes to low power in a dead-headed scenario). Pump 2 came online andcompleted the pumping activity. Pump 1 was saved from doing non value-add work, extending the life of the bearings

Reduction of wear on components: Motor Insights advanced protection offering ensured that the seal on Pump 1did not heat up and therefore did not heat-age, thus the product life is extended

Motor Insight has 12 protective faults and the ability to monitor in real time, providing Motor, Load and Line protection

In this Scenario one of the Load protective settings, Low Power, prevented the heat-aging of the seal

Pump 1s seal would have cost $1,000 to replace

Two motors running to do the work of one wastes additional energy, $????

Reduction in maintenance frequency due to extended life, $????


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Caracteristicas Genericas

Seguridad

Terminal Block IP20 rated terminal block

Terminal blocks are set back from thedisplay to reduce operator shock hazard

Optional Remote Display

Allows for configuration from outside ofthe panel

Facil uso Bright LED display with easy to

understand settings and references

Type 1 Remote display has the sameuser interface as the base unit device

Adjustments to overload settings can bemade without disconnecting power

Line-powered design

Altamente configurable tanto en

protecciones y monitoreo devariables

Fault trip and reset behavior configurable by

fault type

Slow acceleration program

10 Monitoring Choices

Confiabilidad

Enhanced surge and sag withstand capacity

Robust design suited for applications with

high line conditions and poor power quality

Comunicacion Flexible

Multiple communication modules

Can use the communications module

and remote display at the same time

Mejor Diagnosticos

10 fault queueavailable locally

Local interface and monitoring


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Proteccin Configurable

Motor,Load, lineProtection

Thresholds

Motor Protection

Jam (100-400% of FLA)

Current Unbalance (1-30%)

Current Phase Loss (60% fixed)

Ground Fault Current (as low as 0.15 A)*Phase Reversal (ignore, ABC, ACB)

Line Protection

Over voltage (170-660V)

Under voltage (170-660V)

Voltage Imbalance (1-20%)

Load Protection

Under-Current (10-90% of FLA)

Low Power (kW) (lowest power in range)

High Power (kW) (highest power in range)

*not all applications can achieve thislow level GF

Cada falla tiene ajustes

configurables Alarmas disponbles para lineas

y condiciones de falla a tierra


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Configuracion ciclos de partidaAceleracion Lenta

Altas cargas en inercia, cuando parten pueden causar disparos inconvenientes

no deseados conduce a arranques fallidos

Run transition set point 25-125% of FLA

Run transition time 1-180 seconds

Transient state

without

configurable start

cycle, start-up can

be impossible


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Sistema de MonitoreoMonitoreo de.

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*Available in Advanced Configuration menu

*When using communications additional data is available

Start saving time and money byknowing in real time what is

happening at your load

Conserve energy

Optimize your preventive

maintenance

Set alarm conditions


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Comunicaciones Flexibles

CommunicationPort

Remote Display Port

Remote Display and Communication

Modules can be used at the same time

unlike competitive devices

Snap-on modules provide flexibility in

communications options

Modbus Module

DeviceNet +I/O Module

Modbus (+ I/O 120 VAC & 24VDC)

DeviceNet + I/O 120 VAC & 24VDC

Profibus + I/O 120 VAC & 24VDC

I/O has 4 digital inputs and 2 outputs


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DiagnosticosDiagnostics

Motor Insight stores the last 10 faults (best in class) in anon-volatile memory

The fault queue is available locally, through the remote

display, and through communications

All protection faults do not need to be interpreted

During a fault the LEDs jump to the cause of the fault, so

no interpretaion of the fault code is needed.

An example would be if a Jam fault occurred, the display

will show F.14, but simultaneously the LEDs jump to

highlight the Protection Menu, and the Jam Trip % setting

letting the user immediately know that F.14 is a Jam Trip

fault

Full word descriptions with units on the user interface

makes interpretation and setup a breeze

More Diagnostics Available with Motor Insight HMi

Time-stamping faults

Recording more than the last ten faults

Waveform capture when a fault occurs

The ability to look at waveforms in real time

F.14 is a Jam Fault, No Deciphering of

Fault Codes is Needed!


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Capacidad de diagnstico limitadaBi-metal and Electronic Overload Relays

- Fault Indications Possible Cause Possible Cause of the Possible Cause

Number of

Possibilities

Thermal Overload Worn motor bearings 1

Worn pump bushings 2

Increase in motor load 3

Undersized motor 4

Jam Mechanical interference with motor 5

Mechanical interference with driven load 6

Current Unbalance Phase-to-phase leakage path 7

Unbalanced voltage from poor line quality 8

Single-Phasing Loose wire 9

Improper motor wiring 10

Grounded phase 11Open fuse 12

Voltage Unbalance Poor incoming line quality 13

Under Voltage Poor incoming line quality 14

High Power Dead-head positive displacement pump 15

Change in process materials 16

Ground Fault Line to ground leakage path 17

17Number of Inspections required if using a bi-metal or electronic overload =

Thermal Overload Trip Only

(note: electronic overloads can trip for current

unbalance and single phasing, however there is no

separate indication, so all faults appear as thermal

overload)

This chart demonstrates the amount of inspections that have to take place in order

to find the root cause of a thermal overload trip when using a Bi-Metal or an

Electronic Overload

As you can see, for a Thermal Overload trip there could be 17different root

causes, meaning the user has to check 17aspects of their system

If they dont find the true root cause, the failure will occur over and over leading to

unscheduled downtime and loss of productivity


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Diagnosticos disponiblen mejoran laproductividad y ganacias.Motor Insight - Fault Indications Possible Cause

Number of

Possibilities

Thermal Overload

4

Single Phasing

4

Jam Trip

2

Current Unbalance

2Ground Fault 1

High Power

2

Under Voltage 1

Voltage Unbalance 1

Over Voltage 1

Phase Rotation

2

Under Current

2

Under Power 1

Average number of inspections required if using a Motor Insight Overload and Monitoring Relay = 1.92

Rise in line voltage

Change in the load: broken belt, low suction head, dead-headed centrifugal pump

Poor incoming line quality

A mis-wired motor

Inadvertent phase reversal by the utility

Change in the load: broken belt, low suction head, dead-headed centrifugal pump

Dead-head positive displacement pump

Change in process material properties



Mechanical interference with driven load

Phase-to-phase leakage path

Unbalanced voltage from poor line qualityLine to ground leakage path

Worn pump bushings

Increase in motor load

Undersized motor

Loose wire

Improper motor wiring

Grounded phase

Open fuse

Mechanical interference with motor

Worn motor bearings

Due to Motor Insights numerous fault indications, the user can eliminate the

majority of possible causes

This reduces the average number of inspection points from 17 to ~2

Motor Insight also provides fault indications for faults that do not lead to higher

currents, giving you more information about your Load and Line


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Enfoque a la seguridad

Finger Proof

IP20 rated terminal blocks

Terminal blocks are recessed

away from operator interface

Motor Insights Voltage

Terminals are recessed

behind the user interface

and are IP-20 rated

(finger proof)

Competitive Voltage

Terminals Allow for

wire to reach the

user interface

Arc Flash Safety

Optional remote display or the Motor Insight

HMi allow for all configuration and

troubleshooting to be done from outside of

the panel, keeping the door between the

operator and power components

recessed


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Facl uso y programacinInterfaz de usuario

Intuitive, easy to configure

Parameters, monitoring output, and units clearly

described, unlike competitive offerings

Adjustments can be made without disconnecting

power

Bright LED display works at very low temperatures

10 event fault history

Remote Display/HMi

RD same as the base unit, just plug it into the base

unit and it takes control

Unlike competitive devices, no external power supply

is needed and doesnt interfere with communications

Remote Display rated NEMA type 1, 12, and with a

kit, 3R

HMi application available for MCC applications

Terminaes adicionalesI/O

Two terminals provided for each phase input for easy

connection to CPT

Isolated 120 VAC Reset Input

B300 Ground Fault Relay Output

Form C Fault Relay includes 2 common terminals

Wide openings capture wire easily


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3131

Codigos

Reduced Inventory

6 styles achieve FLAs from 1-540 amps and Voltages from170-660 VAC.

Meter, overload relay, GF relay,pump-off controller, resettimers, I/O all in one package!

Saves on stocking costs and

installation time


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Objetivo y Aplicaciones

Target Markets Oil & Gas/Irrigation Water & Wastewater

Mining

Metals Processing

Industrial / Continuous

Process Campuses

Pulp & Paper

Heavy Machinery

EASA Shops

Applications Coal Bed Methane Wells Submersible Pumps

Centrifugal Pumps

Belt/Chain Driven Loads

Low Speed Mixers

Remote Loads in hard toaccess areas

Rail grinders/rock crushers

Previously failed motors tohelp with diagnostics

Dadas las capacidades de configuracin avanzada de Motor Insight tantoen monitoreo, comunicaciones y caractersticas de proteccin se orienta a

cargas y motores crticos dentro del proceso


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C441 Seleccion

Motor Insight Voltage and Current Range Selection using Tables 3 and 4 from the

Catalog, CA042090001E

Scenario 1: 480V, Motor FLA is 30 amps

Selection 1: C441CB, the Crepresents

voltages from 323-528, and the B

represents the 20-90 amp internal CTs

Selection 2: C441DA, the Drepresents

voltages from 489-660, and the A

represents the 2-9 amp internal CTs

Scenario 2: 525V, Motor FLA is 300 amps


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Resumen

Tres beneficios y ventajas de MotorInsight? Mejor Diagnostico, Extension Vida Util, Ahorro de Energia,

Optimizacion de Mantencion

Tres tipos de reles de sobrecarga?

Bi-metal, solid-state/electronic, advanced

Que protocolos de comunicacion se puede integrarcon MotorInsight? Modbus, DeviceNet, Profibus, and Ethernet IP is coming

M t I i ht O l d d


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Wiring:Wire the power cord to the power supply

WhiteLBlackNGreenGround

Wire the Motor Insight to the 24V powersupply

Navigating the Device:The intent is that the device is intuitive

enough that no directions are necessaryMODE/CANCEL

moves the top indicating LEDthrough the 3 menus, protection,operation, and monitor

UP/DOWN ARROWSscrolls through the given menuthat the top indicating LED is

lightingwhen editing, scrolls throughavailable settings

EDIT/SAVEwhen configuring in theProtection or Operation menu,press once to edit, once thesetting starts blinking scroll witharrows, then press again to save

Motor Insight Overload andMonitoring RelayDemo Exercise

Demo Exercise 1- Configure Jam:Press the MODEbutton until theMonitor LED is lit.Scroll through Amps, Volts, Power,Thermal Capacity, using theUP/DOWNarrowsPress the MODEbutton once to lightthe Protection LED

Press the UP/DOWNarrows until theLED for Jam Trip is lit.Press EDIT/SAVE, the displayshould be blinking indicating editingUse the UP/DOWNkeys to set JamTrip % to 300Press EDIT/SAVEto save thissetting

Repeat with other settings

M t I i ht O l d d


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Demo Exercise 2Simulate Under

Power Load Fault:Press the MODEbutton until the MonitorLED is litUse the UP/DOWNarrows to note the KWreading (you will need this value later)Press the MODEbutton once to move tothe Protection menuPress the DOWNarrow until the Low PowerLED is lit

Motor Insight Overload andMonitoring RelayDemo Exercise 2

Press the EDIT/SAVEbuttonUse the UP/DOWNarrows to find aKW value higher than what was notedearlier when you noted KW to themotor. Once set, this will trigger afaultPress the EDIT/SAVEbutton to storethis value as your Low Powerthreshold and then quickly press themode button to move to the nextmenuYou will shortly (5 seconds) see a tripcaused by the power in the simulationbeing under the threshold you just setNote both the fault code (F.15) ANDthe LED for Low Power is lit up, thus

no need to interpret fault codes, aslong as it is a protection type fault theLED will be lit


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Configuracin Tipica


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Conexin de CTs - Interpretacin


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Conexin de CTs - Interpretacin


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3.- c441 motor insight training.pdf

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