3.- c441 motor insight training.pdf
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2008 Eaton Corporation. All rights reserved.
This is a photographic templateyourphotograph should fit precisely within this rectangle.
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
90-540A con CTs externos
89-660V line power)1-90A sin CTs externos
90-540A con CTs externos
(93.5-132 control power)1-90A sin CTs externos
90-540A con 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.
Motor InsightsCapacidad Protectora
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
Motor InsightsCapacidad Protectora
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 InsightsCapacidad Protectora
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
Motor InsightsCapacidad Protectora
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
Motor InsightsCapacidad Protectora
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
Motor InsightsCapacidad Protectora
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
Poor incoming line quality
Poor incoming line quality
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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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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2008 Eaton Corporation. All rights reserved.
This is a photographic templateyour
photograph should fit precisely within this rectangle.
Preguntas?
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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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This is a photographic templateyour
photograph should fit precisely within this rectangle.
Preguntas?