Artesis MCM Operating Manual

MCM User's Manual

Document ID: MCM-OP-UM-EG-0091.0000

MCM User's Manual

WARNING

Lethal voltages and currents are present at the input terminals of this device. Accordingly, this MCM unit should be installed and maintained only by qualified, competent personnel who have the necessary training and experience appropriate to high voltage and current devices. MCM must be used in accordance with all local and national codes for the installation and operation of electrical equipment.

Recommended safety precautions should be followed at all times. Both current and voltage transformers can present lethal currents and voltages when their primaries are energized and standard practices (i.e. shorting the secondaries of current transformers and removing voltage transformer fuses) must be respected during installation or any subsequent service.

The unit is designed for operation in a control cabinet with restricted access to the rear terminals and should not be used in any environment where this is not the case. MCM should not be used for the purpose of primary protection of electrical equipment.

MCM User's Manual

Motor Condition Monitor (MCM) and MCMSCADA

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, mechanical, photocopying, recording or otherwise, without prior written permission of Artesis AS. No patent liability is assumed with respect to the information contained herein.

Whilst every effort has been made to ensure that the information presented in this document is accurate and up to date, Artesis AS reserves the right to make changes without notice. Neither Artesis AS nor its designated agents can be held responsible for any errors or omissions, or problems arising from the application of information contained herein.

Neither Artesis AS nor its affiliates shall be liable to the purchaser of this product or third parties for damages, losses, costs, or expenses incurred by purchaser or third parties as a result of: accident, misuse or abuse of this product or unauthorized modifications, repairs, or alterations to this product, or failure to comply strictly Artesis AS’s operating and maintenance instructions.

Artesis AS shall not be liable against damages or problems arising the use of any options or any consumable products other than those designated as Artesis original products or Artesis approved products by Artesis AS.

Product names other than those owned by Artesis AS are used for identification purposes only and may be trademarks of their respective owners. Artesis AS disclaims any and all rights in those marks.

MCM User's Manual

Table of Contents

Section I

Section II

Section III

Welcome to MCM

................................................................................................................................... 11 Introduction

................................................................................................................................... 12 Use of this manual

MCM Installation

................................................................................................................................... 31 Preliminary checks

................................................................................................................................... 32 MCM Unit Installation

................................................................................................................................... 43 Current and Voltage Sensor Installation

.......................................................................................................................................................... 4Low voltage line driven systems

.......................................................................................................................................................... 4Low voltage inverter driven systems

.......................................................................................................................................................... 5Medium/High voltage systems

................................................................................................................................... 54 Rear panel connections

................................................................................................................................... 65 Applying power to the MCM unit

................................................................................................................................... 76 Installing with soft-starter systems

................................................................................................................................... 77 Installing with inverter drives

MCM Use

................................................................................................................................... 81 Introduction

................................................................................................................................... 82 The front panel

................................................................................................................................... 93 Configuring for use

.......................................................................................................................................................... 9Entering the password

.......................................................................................................................................................... 10The Edit Settings menu

......................................................................................................................................................... 10First time use

......................................................................................................................................................... 11Calibration factors

......................................................................................................................................................... 11Motor settings

......................................................................................................................................................... 11Communications settings

................................................................................................................................... 124 Running MCM

.......................................................................................................................................................... 12Introduction

.......................................................................................................................................................... 12Alarm messages and status indication

.......................................................................................................................................................... 13Running CHECK MOTOR

.......................................................................................................................................................... 14Setting and checking the input connections

.......................................................................................................................................................... 14Running LEARN and IMPROVE

.......................................................................................................................................................... 16Running RESUME and UPDATE

.......................................................................................................................................................... 17Advanced use

.......................................................................................................................................................... 19Equipment Faults and Their Diagnoses Using MCM

.......................................................................................................................................................... 21Interpreting MCM fault indications

......................................................................................................................................................... 21MCM status values

......................................................................................................................................................... 22Changes in line voltages

......................................................................................................................................................... 22Load changes

......................................................................................................................................................... 22Error messages

......................................................................................................................................................... 23Using the relay output

......................................................................................................................................................... 24Connecting to the serial port

MCM User's Manual

Table of Contents

Section IV

Section V

Troubleshooting

................................................................................................................................... 261 Introduction

................................................................................................................................... 262 Use of the MCM Config utility

................................................................................................................................... 293 Fault diagnosis

................................................................................................................................... 304 Servicing

Appendices

................................................................................................................................... 311 Appendix 1: MCM Error, alarm and warning conditions

................................................................................................................................... 342 Appendix 2: Current and voltage sensor selection

................................................................................................................................... 363 Appendix 3: Connection Diagrams

................................................................................................................................... 394 Appendix 4: Menu settings and parameters

................................................................................................................................... 405 Appendix 5: Edit Settings Menu items

................................................................................................................................... 456 Appendix 6: Flowcharts for MCM use

................................................................................................................................... 517 Appendix 7: Continuous device ratings

iii

MCM User's Manual

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1 Welcome to MCM

1.1 Introduction

MCM is a revolutionary tool in the battle to keep electric motors and machinery running at peak performance, whilst maintaining high plant productivity levels. Used correctly, this unique instrument is capable of monitoring three phase AC motors of all sizes and power levels to provide clear, unambiguous indications when the performance of a particular motor (or even the machinery it is connected to) begins to degrade. The numerous transducers employed by other, less advanced instruments have been replaced by three current sensors and three voltage sensors, familiar to all those involved with the measurement of electrical quantities, making the system straightforward to install and use without indepth training of personnel.

In addition to its unique capabilities as an intelligent condition-monitoring device, MCM can also perform many of the functions of, and indeed replace the more traditional energy monitoring and data-logging instruments.

For applications involving the monitoring of many motors and associated machinery, the networking options available with MCM allow units to be connected together to a host terminal where they can all be viewed together.

Section 1 - Welcome to MCM

Furthermore, the monitoring software package allows examination of the various parameters MCM uses to determine the status of a motor and to trend the parameters as a visual indication of degradation over time.

Despite its simplicity and ease of use, like any intelligent electronic, software-based device, it is important that MCM is installed and used correctly. We recommend strongly that you take the time to study the information contained within the accompanying manuals and to familiarize yourself with the operating principles and practices.

Customer service: Please contact either your supplier or Artesis AS Customer Service if you experience any problems in the installation or use of MCM.

1.2 Use of this manual

This manual explains the basic concepts needed to install and use MCM. The appendix at the end of the manual provides information that may be useful to the general user. For further, specific details please

MCM User's Manual

contact Artesis AS.

Section 1 - Welcome to MCM

MCM User's Manual

In common with any device connected to high power electrical supplies, only suitably qualified personnel should install and maintain MCM.

2 MCM Installation

2.1 Preliminary checks

Please inspect the contents of the MCM package and ensure that they agree with the information in the Packing list. In the event of any missing or damaged items, please contact your supplier immediately. Check also that the power range of the MCM unit is suitable for the motor to be monitored. The device type can be found on the MCM label. Artesis A.S. will not accept responsibility for damage caused to or by any MCM unit that has been incorrectly installed or installed on a motor system outside the indicated power range.

2.2 MCM Unit Installation

Section 1 - Welcome to MCM

MCM has been designed to mount directly onto the front panel of the motor switchgear cabinet. Any other usage is not recommended due to the lethal voltages present at the terminals. To mount,

insert the MCM unit into the prepared 91x91 mm cutout on the cabinet panel and push until the front of the unit is flush with the panel. Insert the side retainers and tighten the thumbscrews on each retainer until the MCM unit is held securely in place.

Mounting MCM on a panel

MCM User's Manual

Dangerous and lethal voltages can develop across the secondary terminals of open circuit current and voltage transformers. Before disconnecting any MCM unit to or from a current transformer, the secondary terminals of the transformer should be shorted using a link capable of carrying at several times the nominal output current (i.e. at least 10A). Before performing any work on a voltage transformer, its fuse must be removed or switch opened. Contact breakers or fuses at their sources must protect all voltage inputs.

2.3 Current and Voltage Sensor Installation

2.3.1 Low voltage line driven systems

Three standard 5A secondary, current transformers of appropriate ratings are recommended for current sensing (please refer to the appendix at the end of this manual for full specifications). The secondary terminals of each transformer should be connected to the corresponding current measurement terminal pairs, I11-I

Voltage line connections VR, VS, VT should be made directly to their respective voltage measurement terminals V1, V2, V3 at the rear of the unit.

12, I21-I22, I31-I32

, on the rear of the MCM unit.

Section 2 - MCM Installation

Please refer to the connection diagrams in the appendix at the end of this manual for further details.

2.3.2 Low voltage inverter driven systems

The current sensors employed by MCM for inverter driven systems are Hall-effect type requiring an external DC power supply. The motor current rating should be checked carefully to ensure compatibility with the sensors provided. Please refer to the appendix at the end of this manual for further details on sensor selection.

High current sensors (for currents greater than 200 A) need to be mounted separately at a convenient location within the switchgear cabinet together with their external power supplies. Smaller sensors are mounted on the same circuit board as the power supply and should be placed together at the chosen location. In both cases, the cable carrying power to a single phase of the motor must be passed through the central hole in the appropriate current sensor and secured.

The power supply ground should be connected directly to the I12, I22, I32 pairs of current measurement terminals on the rear of the MCM unit. Voltage connections VR, VS, VT should be made directly to their respective voltage measurement terminals V1 V2 V3 at the rear of the unit.

Note that MCM is not recommended for use with inverters operating at a chopping frequency lower than 2 kHz.

Please refer to the connection diagrams in the appendix at the end of this manual for further details.

MCM User's Manual

If compensation capacitors are employed, it is essential that the current transformers be placed between the motor and the capacitor bank so that only the true motor currents are measured.

REMOVE ALL POWER PRIOR TO CHANGING CONNECTIONS

2.3.3 Medium/High voltage systems

Three standard 5A secondary, current transformers of appropriate ratings are recommended for current sensing (please refer to the appendix at the end of this manual for full transformer specifications). The secondary outputs from each transformer should be connected to the corresponding current measurement terminal pairs, I11-I

Standard 100V, 110V and 120V secondary voltage transformers should be used to drop the voltage to usable levels. Connections from the secondary outputs of the transformers should be made to the respective voltage measurement terminals V1, V2 V3 at the rear of the unit.

Please refer to the connection diagrams in the appendix at the end of this manual for further details.

12, I21-I22, I31-I32

Section 2 - MCM Installation

, on the rear of the MCM unit.

2.4 Rear panel connections

Connections to the MCM rear panel are given in the following figure. Lethal voltages can be present at the voltage and current terminals and it is vitally important that power is removed from both the motor and the MCM unit prior to any connections being changed.

The three motor power voltages should be connected to the corresponding measurement terminals on the MCM rear panel (R phase to V1, S phase to V2, and T phase to V3) using the connectors provided. Similarly, the IR, IS, IT connections from the current sensors should be made to the appropriate current terminal pairs, I11-I

12, I21-I22, I31-I32,

sets of phases have the correct phase relationship as the phase ordering is determined by MCM.

The order of these voltage and current pairs is not important as MCM determines the correct ordering when CHECK MOTOR is first run on the device

on the upper part of the rear panel. It is not essential that the all three

MCM User's Manual

Protection against pickup of electromagnetic interference on the power lines:

Section 2 - MCM Installation

In order for the unit to function within the harsh electrical environments often found in switchgear enclosures and to conform fully with emission standards, it is strongly recommended that all attached cables be passed twice through the ferrite rings delivered with the product to their MCM sockets.

A circuit breaker should be provided on the power line in close proximity to the MCM unit. The circuit breaker should be clearly marked as the power switch for the device.

Please note that in order to function at its full capability, MCM requires that the case be connected using a low impedance cable (12 – 14 AWG cable is recommended) directly to a high quality ground via the ground terminal on the power connector. If a suitable ground is not provided, fault free operation within specifications cannot be guaranteed.

2.5 Applying power to the MCM unit

Once the motor connections have been made to the rear panel, power should be applied to the unit. MCM requires between 85 and 240VAC obtained from a single phase, neutral and ground. At this stage, the Power indicator at the left of the front panel will light. If this does not occur, please check that the correct voltages have been applied. Immediately on application of power, the LED condition indicators should briefly flash and activity should be seen on the main display. The text "Initialising" followed by a series of dots will appear.

"Initializing.... "

After a few seconds, the display should indicate that it is in the IDLE mode. MCM is now ready for use. When using a device for the first time the message "Bad flash data! Press Clear" may be displayed. In this case press the CLEAR button several times until the message disappears. Once a valid learn mode has been completed, this message should not occur again.

MCM User's Manual

2.6 Installing with soft-starter systems

MCM can be installed with standard soft-starter systems provided that they are automatically bypassed immediately after motor start-up and during subsequent use. Un-bypassed, soft-starter systems can introduce considerable distortion into the current waveforms and thus prevent MCM from modeling the properties of the motor itself. If MCM is to be used with such a system, it is essential that the maximum current limit of the starter be above the nominal running motor current so that it is bypassed effectively during all normal operation. MCM should never be used on a system that employs soft-starters for speed control or other un-bypassed uses. Please refer to the diagrams in the appendix for details of the connections needed for soft starter systems. Soft-starters should always be bypassed.

2.7 Installing with inverter drives

Using MCM with inverter driven motors requires the same voltage connections specified for line driven systems. External Hall-effect current sensors must be used with inverter systems, as normal current transformers have insufficient bandwidth for use with the range of frequencies obtainable from inverters. Please refer to the diagram in the appendix for details of the connections needed for inverter driven systems.

Section 2 - MCM Installation

MCM User's Manual

3 MCM Use

3.1 Introduction

Use of MCM is both simple and straightforward once the basic concepts and principles are understood. This section of the manual is designed to introduce these concepts and to demonstrate how MCM is set up, how to check all the connections and settings, how MCM learns the characteristics of the system it will monitor and finally how to actually monitor the motor system. It is recommended that first time users read this section carefully, as successful operation requires that MCM is set up and used correctly.

Flowcharts for the main operations are provided in the appendix at the end of this manual to help users navigate their way through the various steps involved with setting and running MCM for the first time.

3.2 The front panel

Section 2 - MCM Installation

Confirming ENTER and CLEAR:

Once the sensors have been connected and power has been applied to the MCM unit, the Power indicator light and the Liquid Crystal Display (LCD) on the front panel should both be lit. The LCD should display the message IDLE on the top line, indicating that the unit is idle and waiting input from the user. When being used for the first time, the message Bad flash data! Press Clear may be displayed. The user should repeatedly press the CLEAR button until the message disappears. Once data has been written to flash this message should not occur again.

MCM User's Manual

Using the front panel buttons:

Commands are input by pressing one of the six selection buttons on the front of the unit, UP, DOWN, LEFT, RIGHT, ENTER and CLEAR. For instance, the user can cycle through the various modes (IDLE

to CHECK MOTOR to RUN to RESUME … and finally back to IDLE), by repeatedly pressing the UP button. A particular mode can be selected by pressing ENTER when the desired mode is displayed on the LCD. The menus are set up on a hierarchical basis, with each level representing commands of the same precedence which the user can cycle through by pressing the UP or DOWN buttons. Pressing

CLEAR has the effect of stopping a particular action and rising up a level in the hierarchy. Only Edit Settings has nested hierarchy levels more than two deep. In general whenever ENTER or CLEAR is

pressed, it will be necessary to confirm the action with a second press of the button; pressing the other button (i.e. CLEAR after ENTER and vice versa) will cancel the action.

Setting numeric values:

Section 3 - MCM Use

Similarly, numeric values can be entered using the arrow buttons. When a value is to be changed, use the LEFT or RIGHT buttons to move the LCD flashing cursor to the first digit to be edited and repeatedly press either the UP or DOWN buttons to scroll through the available alphanumeric characters until the desired one is displayed. Subsequent digits can be edited by moving to the next digit using the LEFT or RIGHT buttons and again scrolling with the UP and DOWN buttons. A schematic diagram showing the menu hierarchy is shown in the appendix at the end of this manual.

3.3 Configuring for use

Master reset:

When first installed, the MCM unit will be configured for the default, factory settings which will need to be changed prior to use. At later times, the factory settings can be restored by pressing and holding down the LEFT button for about 4 seconds during power up of the device, until the string; Press ENTER for general reset appears. At this stage pressing ENTER will initiate the reset. Pressing any other button will cause the reset to be ignored and the device will continue.

3.3.1 Entering the password

To configure the unit, select the Edit Settings mode and press and confirm ENTER. In order to proceed further, it will be necessary to enter a password. The factory setting for this password is the string “m“ and can be entered using the UP and DOWN buttons to cycle through the alphanumeric characters (‘a’ through ‘z’, ‘0’ through ‘9’). The LEFT and RIGHT buttons are used to shift the active character in the string. To input the password “m”, repeatedly press the UP button until the letter ‘m’ appears in the first position. Press and confirm ENTER and then press ENTER again to enter the Edit Settings menu. It is recommended that at a later time the password be changed, in order to prevent unauthorized access to the device.

MCM User's Manual

Motor values Harmonic values Comm. settings Motor settings Calibration

Alarm thresholds Versions Run settings Phase Ordering Change password

3.3.2 The Edit Settings menu

At this level the following Edit Settings menu items are accessible:

Editing and displaying menu items:

Please refer to the appendix for a table of these menus and their sub-menu items. To edit a particular item, first select the item to edit and press and confirm ENTER. As before use the UP and DOWN buttons to scroll vertically through individual digits and the LEFT and RIGHT buttons to change the digit being edited. Some variables can only take discrete values represented by character strings and in this case vertical scrolling will shift through the allowed values. For example, the Parity value under the Communications settings menu can only have the values EVEN or ODD and scrolling will repeatedly cycle through these values.

Section 3 - MCM Use

Menu paths:

Throughout this manual, paths to menu items are represented by the word MENU: followed by the list of sub-menus required to reach the item separated by a forward slash. For example the path of the Parity value given in the preceding paragraph would be given as:

MENU: Edit Settings / Password / Comm. Settings / Parity The forward slash can be thought to represent the action of pressing and confirming ENTER.

Local Lockout and passwords:

Some modes can be protected for supervised access by setting the local lockout setting. MENU: Edit Settings / Password / Run Settings / Local Lockout If this mode is set, access to the following modes is password protected: (i) CHECK MOTOR

(ii) RUN (iii) RESUME (iv) UPDATE

In addition, canceling any of these modes by pressing CLEAR also requires the user to supply a password. All passwords are the same as that used to access Edit Settings.

3.3.2.1 First time use

Before MCM can be used for the first time it is necessary to change various settings from their default values (a table outlining the MCM settings is shown in the appendix). Values relevant to the connected motor must be set for the quantities described in the following sections.

MCM User's Manual

3.3.2.2 Calibration factors

Hall-effect current sensors and assemblies supplied with MCM should be accompanied by a calibration document containing the sensor’s calibration factor. The values of each calibration factor should be entered into the correct setting under the Calibration menu. It is important that the correct factor be entered for each channel, as MCM will not function correctly if the calibration factors are incorrect.

For channels connected to transformer sensors, the calibration factor should be equal to the nominal ratio of the primary to secondary turns. For example a 100A current transformer with a 5A output and a single primary turn would require a calibration factor of 20. The same transformer with two primary turns would require a calibration factor of 10. A 6500V voltage transformer with a nominal secondary voltage of 100V would require a calibration factor of 65. Any channel connected directly to the motor without an

external sensor (i.e. voltage connections on low voltage units) requires a calibration factor of 1.

3.3.2.3 Motor settings

Nominal voltage, current and frequency:

The nominal voltage, current and speed (in rpm) of the attached motor must be entered under the Motor Settings menu. These values can be obtained from the motor specifications. MCM uses these values to

determine whether the motor complies with its specifications and incorrect values are likely to raise alarms. The nominal line frequency (or most commonly expected frequency in the case of an inverter) should also be set. Similarly, the motor connection type must be set to one of Star or Delta.

Section 3 - MCM Use

3.3.2.4 Communications settings

Setting the device address:

If the MCM networking options are to be used, the MCM network address must be supplied. By default this is set to 0, which by convention is the address of the host terminal. Use of this address will therefore disrupt communications over the network and must be changed prior to connection. Any address between 1 and 255 can be selected although it is important to check that the selected address is not in use by any other device on the same node. Please refer to the MCMViewPro networking documentation for full details of address selection.

It is recommended that the motor serial number (or any other short identifier string) be entered as a means of identifying the motor to the software. This is not obligatory, and both the networking software and MCM can function without this information.

Other communications settings:

All other communications settings should be left at the factory defaults if the MCMSCADA networking software is being used. If another software package is employed (i.e. SCADA software), please refer to its documentation for communication settings. MCM can use both 2 and 4 wire (RS 422 and RS485 standards respectively) communications at up to 19200 Baud. Please refer to section 4.4.12 for further information.

MCM User's Manual

STATUS STRING

LED No

Fault Severity LEARN

MCM has insufficient data to assess the status of equipment

NORMAL

Motor is healthy or level of failure is under alarm thresholds

WATCH LINE

There is a changing on the supply voltage of the motor. Temporary

changes in supply voltage cause this alarm. If alarm is persistent check; harmonic levels, capacitors, isolation of cables, motor connector or terminal slackness, loose contactors, etc.

3.4 Running MCM

3.4.1 Introduction

Having configured MCM for a particular motor, it can now be used for its intended purpose of monitoring and assessing the condition of the motor. In general, this involves first running MCM to measure and learn the properties of the motor and then running MCM in its test mode to perform the actual monitoring. Without the learning period MCM has insufficient information on which to base its decisions as the motor ages and will not perform to its specifications. For this reason, MCM ensures that a valid learning period is first performed before allowing the user to request the device to monitor the motor.

3.4.2 Alarm messages and status indication

Alarms specific to the motor:

MCM divides warning messages into the categories of warnings, alarms and errors. Warnings inform the user that non-critical conditions have arisen that the user should be aware of but do not affect the performance of MCM. Alarms provide information specific to the motor being tested and are indications of faults caused by incorrect connections to the motor, the supplied line voltage and/or motor currents being outside the specified limits and other conditions that prevent MCM from correctly determining the state of the motor. Alarms do not cause MCM to stop monitoring completely, but generally are indications that there is something that needs to be investigated and possibly changed before MCM can function to its full extent. In some cases an alarm may indicate a transient event such as high line voltages, which although damaging to the motor in the long term, do not indicate an immediate need for action. Of course if the frequency of such events is sufficiently high, the cause should be located and corrective action taken to remedy the problem. It is important to realize that when an alarm is displayed, MCM cannot monitor the motor status. It is therefore important to ascertain the cause of the alarm at the earliest opportunity.

Section 3 - MCM Use

Viewing alarm messages:

An alarm is indicated on the front panel of MCM by the message Alarm followed by a hexadecimal value. The bits of the hexadecimal value refer to which alarm is raised. Repeatedly pressing the RIGHT or LEFT buttons cycles through a list of all active alarms. Please refer to the appendix for a complete list of possible alarm conditions and their remedies. The measured physical motor values can be viewed during an alarm by pressing the UP or DOWN buttons. This is often useful in determining the reason for an alarm.

Fault status indication:

+ 39 hidden pages

Artesis MCM Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Welcome to MCM

1.1 Introduction

1.2 Use of this manual

2 MCM Installation

2.1 Preliminary checks

2.2 MCM Unit Installation

2.3 Current and Voltage Sensor Installation

2.3.1 Low voltage line driven systems

2.3.2 Low voltage inverter driven systems

2.3.3 Medium/High voltage systems

2.4 Rear panel connections

2.5 Applying power to the MCM unit

2.6 Installing with soft-starter systems

2.7 Installing with inverter drives

3 MCM Use

3.1 Introduction

3.2 The front panel

3.3 Configuring for use

3.3.1 Entering the password

3.3.2 The Edit Settings menu

3.3.2.1 First time use

3.3.2.2 Calibration factors

3.3.2.3 Motor settings

3.3.2.4 Communications settings

3.4 Running MCM

3.4.1 Introduction

3.4.2 Alarm messages and status indication