Skf EXP4000 User Manual

SKF Dynamic Motor Analyzer

EXP4000

User manual

SKF Dynamic Motor Analyzer

EXP4000

User manual

Part number: 71-005 EN

Revision: V6

Copyright © 2012 by Baker Instrument Company, an SKF Group Company
All rights reserved.

Baker Instrument Company, an SKF Group Company

4812 McMurry Ave. Suite 100
Fort Collins, CO 80525
[phone]
[phone] (FAX)
800-752-8272 (USA Only)
http://www.skf.com/group/products/condition-monitoring/electric-motor-testing/index.html

Information furnished in this manual by Baker Instrument Company, an SKF Group Company,
is believed to be accurate and reliable. However, Baker Instrument Company, an SKF Group
Company, assumes no responsibility for the use of such information or for any infringements
of patents or other rights of third parties that may result from its use. No license is granted
by implication or otherwise under any patent rights of Baker Instrument Company, an SKF
Group Company.

No part of this document may be reproduced in part or in full by any means, such as
photocopying, photographs, electronic recording, videotaping, facsimile, and so on without
written permission from Baker Instrument Company, an SKF Group Company, Fort Collins,
Colorado.

NOTICE

Baker Instrument Company—an SKF Group Company—assumes no
liability for damages consequent to the use of this product.

SKF Patents

#US04768380 • #US05679900 • #US05845230 • #US05854553 • #US05992237 •
#US06006164 • #US06199422 • #US06202491 • #US06275781 • #US06489884 •
#US06513386 • #US06633822 • #US6,789,025 • #US6,792,360 • US 5,633,811 • US
5,870,699 • #WO_03_048714A1

Notices

CAUTION

This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC rules. These limits are
designed to provide reasonable protection against harmful interference with
the equipment is operated in its installation.

This equipment generates, uses, and can radiate radio frequency energy
and, if not installed and used in accordance with the product manual, could
cause harmful interference to radio communications. If this equipment
does cause harmful interference, the user will be required to correct the
interference. Due to the phenomena being observed and the material
properties being measured, this equipment radiates radio frequency energy
while in the active test mode. Care should be taken to ensure this radio
frequency energy causes no harm to individuals or other nearby equipment.

Intended use of instrument

The EXP4000 is intended for detection motor efficiency and physical performance
deterioration, and other electrical problems within electric machines by trained professionals.
It is intended to perform only the specified tests that this manual explains in detail. Please
refer to chapters in this manual concerning specific operation of the instrument.

Note on software

While the UNIT is a Microsoft Windows® based instrument, it is specially configured and
optimized to perform the functions for which it was designed. The loading or operation of
unauthorized software may cause the instrument to malfunction or cease functioning and
may void the manufacturer’s warranty.

ii Dynamic Motor Analyzer—EXP4000 User Manual

Notices

Declaration of conformity
Manufacturer’s Name & Address:
Baker Electrical Instrument Company, an SKF Group Company
4812 McMurry Ave
Fort Collins, CO 80525 USA
Equipment Description: On-Line Motor Monitor
Equipment Model Designations: EXP4000
Application of Council Directive 72/23/EC on the harmonization of the laws related to

Member States relating to electrical equipment designed for use within certain voltage limits,
as amended by: Council Directive 93/68/EC and Council Directive 2004/108/EC on the
approximation of the laws related to Member States relating to the electromagnetic
compatibility, as amended by: Council Directive 93/68/EC. Note: due to the phenomena
being observed and the material properties being measured, this equipment does radiate
radio frequency energy while in the active test mode.

Referenced Safety Standards:
EN 61010-1
Referenced EMC Standards:
EN 61326:2001
EN 55011 Class A
EN 61000-3-2
EN 61000-3-3
EN 61000-4-2
EN 61000-4-3
EN 61000-4-4
EN 61000-4-5
EN 61000-4-6
EN 61000-4-8
EN 61000-4-11
I, the undersigned, hereby declare that the equipment specified above conforms to the above

Directives and Standards.
Signature:

Printed Name: Erik A. Stolz
Title: Electrical Engineer

Dynamic Motor Analyzer—EXP4000 User Manual iii

Notices

Software License Agreement

UNIT—test equipment and desktop versions

Carefully read the following terms and conditions before opening the software envelope or
operating the UNIT. Either opening the envelope or using the software constitutes your
acceptance of these terms and conditions on behalf of any party using the instrument (the
“User”). If you or the User do not agree with these terms, promptly return the instrument
with the envelope unopened for a full refund.

1. Definitions

(a) Computer Software: A Software program provided with the Instrument on CD or other
physical medium for installation and use on the User’s desktop computer(s) or servers, and
all updates, upgrades, enhancements and modifications provided directly or indirectly to the
User from time to time.

(b) Documentation: This User Manual and other manuals and documentation relating to the
Instrument and provided directly or indirectly to the User in the original Instrument carton or
from time to time thereafter.

(c) Instrument: The unit of test equipment with which this User Manual was provided to the
User.

(d) Instrument Software: The software program pre-loaded on the Instrument, and all
updates, upgrades, enhancements and modifications provided directly or indirectly to the
User from time to time.

(e) Software: The Instrument Software and/or Computer Software, as the context requires.
(f) Intellectual Property Rights: All rights arising or protectable under the copyright,

trademark, patent, or trade secrets laws of the United States or any other nation, including
all rights associated with the protection of computer programs and/or source code.

(g) Person: An individual, a partnership, a company, a corporation, an association, a joint
stock company, a trust, a joint venture, an unincorporated organization, or a governmental
entity (or any department, agency, or political subdivision thereof).

2. License; Related Terms

(a) Grant of License. SKF grants the User, pursuant to the terms and conditions of this
Software License, a non-exclusive, non-transferable, and revocable license to (i) use the
Instrument Software only on the Instrument, (ii) the Computer Software(s) on the numbers
and types of desktop and/or other computers specified elsewhere in this User Manual, (iii)
reproduce the Software only as necessary to use it and create no more than two copies of the
Software in machine readable form for back-up purpose only; provided in each case that the
copy shall include SKF CMC-Fort Collins (formerly Baker Instrument Company)’s copyright
and any other proprietary notices, and (iv) utilize the Documentation only in conjunction with
the use of the Software.

(b) Restrictions on Use. The User shall not (i) permit any parent, subsidiaries, affiliated
entities or third parties to use the Software; (ii) grant third parties use of the Software on a
service bureau, application service provider or other similar basis; (iii) rent, resell, lease,
timeshare or lend the Software to any Person; (iv) sublicense, assign, or transfer the
Software or this license for the Software to any third party, (v) reproduce the Software other
than as expressly authorized herein, or distribute, or publicly display the Software; (vi) make
the Software accessible to any Person by any means, including posting on a web site or
through other distribution mechanisms over the Internet; (vii) reverse assemble,
disassemble, reverse engineer, reverse compile, decompile, or otherwise translate the
Software or prepare Derivative Works based on the Software; (viii) place, reproduce, or make
available the Software on the User’s computer network if the User is only authorized by this
Software License to operate the Software on a single workstation; (ix) exceed at any given

iv Dynamic Motor Analyzer—EXP4000 User Manual

Notices

point in time the total number of network clients authorized by the applicable purchase order
or ordering document to use or access the Software; or (x) edit or modify the Software except
as expressly authorized by SKF CMC-Fort Collins (formerly Baker Instrument Company),
including altering, deleting, or obscuring any proprietary rights notices embedded in or
affixed to the Software.

(c) Protection of Software. The User will take action by instruction, written agreement, or
otherwise as appropriate with any person permitted access to the Software to enable the
User to comply with its obligations hereunder.

(d) Material Terms and Conditions. The User acknowledges that each of the terms and
conditions of this Section 2 is material and that failure of the User to comply with these terms
and conditions shall constitute sufficient cause for SKF to terminate this Software License
and the license granted hereunder immediately and without an opportunity to cure. This
subsection 2(d) shall not be construed to preclude, or in any way effect, a finding of
materiality with respect to any other provision of this Software License.

3. Ownership

SKF CMC-Fort Collins (formerly Baker Instrument Company), as between SKF and the User,
owns all Intellectual Property Rights related to the Software, including custom modifications
to the Software, whether made by SKF or any third party. The User agrees that this Software
License effects a license, not a sale, of the Software and that the first sale doctrine, as
codified in 17 U.S.C. § 109, does not apply to the transaction effected by this Software
License.

4. Confidential Information

The Software contains proprietary information, including trade secrets, know-how and
confidential information (hereinafter referred to collectively as the “Confidential Information”),
that is the exclusive property of SKF CMC-Fort Collins (formerly Baker Instrument Company).
During the period this Software License is in effect and at all times after its termination, the
User and its employees and agents shall maintain the confidentiality of the Confidential
Information and shall not sell, license, publish, display, distribute, disclose or otherwise make
available the Confidential Information to any Person nor use the Confidential Information
except as authorized by this Software License. The User shall not disclose the Confidential
Information concerning the Software, including any flow charts, logic diagrams, user
manuals and screens, to persons not an employee of the User without the prior written
consent of SKF CMC-Fort Collins (formerly Baker Instrument Company).

5. Limited Warranties; Disclaimer

(a) SKF CMC-Fort Collins (formerly Baker Instrument Company)’s sole and exclusive
warranties with respect to the Instrument and Software are set forth in this User Manual.

(b) EXCEPT AS SET FORTH IN THIS User Manual AND TO THE EXTENT PERMITTED BY
APPLICABLE LAW, ALL EXPRESS AND/OR IMPLIED WARRANTIES OR CONDITIONS,
INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OR CONDITIONS OF
MERCHANTABILITY, MERCHANTABILITY OF A COMPUTER PROGRAM, INFORMATIONAL
CONTENT, SYSTEM INTEGRATION, FITNESS FOR A PARTICULAR PURPOSE, AND NON­INFRINGEMENT, ARE HEREBY DISCLAIMED AND EXCLUDED BY SKF CMC-FORT COLLINS
(FORMERLY BAKER INSTRUMENT COMPANY).

6. Limitations on Liability

(a) Limitations and Exclusions. IN NO EVENT WILL SKF BE LIABLE TO LICENSEE FOR ANY
DIRECT, INDIRECT, INCIDENTAL, CONSEQUENTIAL, PUNITIVE OR OTHER SPECIAL
DAMAGES, LOST PROFITS, OR LOSS OF INFORMATION SUFFERED BY LICENSEE ARISING
OUT OF OR RELATED TO THE INSTRUMENT OR THE USE OF THE INSTRUMENT, FOR ALL
CAUSES OF ACTION OF ANY KIND (INCLUDING TORT, CONTRACT, NEGLIGENCE, STRICT
LIABILITY, BREACH OF WARRANTY OR CONDITION, AND STATUTORY) EVEN IF SKF HAS

Dynamic Motor Analyzer—EXP4000 User Manual v

Notices

BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THE PRECEDING EXCLUSION
AND DISCLAIMER OF DAMAGES SHALL APPLY TO ALL CLAIMS MADE BY LICENSEE
RELATED TO OR ARISING OUT OF LICENSEE’S USE OF THE SOFTWARE, INCLUDING, BUT
NOT LIMITED TO, CLAIMS ALLEGING THAT THE SOFTWARE, OR ANY COMPONENT
THEREOF, FAILED OF ITS ESSENTIAL PURPOSE OR FAILED IN SOME OTHER RESPECT.

(b) Acknowledgment. The User agrees that the limitations of liability and disclaimers of
warranty set forth in this Software License will apply regardless of whether SKF has tendered
delivery of the Software or the User has accepted the Software. The User acknowledges that
SKF has set its prices and granted the licenses contemplated herein in reliance on the
disclaimers of warranty and the limitations and exclusions of liability set forth in this
Software License, and that the same form an essential basis of the bargain between the
Parties.

7. Term and Termination

(a) Term. The licenses granted herein shall commence on the User’s acceptance of the terms
of this Software License, and shall continue in existence until it is terminated in accordance
with Section 7(b) below.

(b) Termination. SKF may terminate this Software License and the license conveyed
hereunder in the event that the User breaches any provision, term, condition, or limitation set
forth in this Software License, including but not limited to the license restrictions set forth in
Section 2(b) of this Software License.

(c) Effect of Termination. Within ten (10) days after termination of this Software License and
the licenses granted hereunder, the User shall return to SKF CMC-Fort Collins (formerly
Baker Instrument Company), at the User’s expense, the Computer Software and all copies
thereof, and deliver to SKF a certification, in a writing signed by an officer of the User, that all
copies of the Computer Software have been returned to SKF and that the User has complied
with the requirements of this Section 7(c).

8. Assignment

The User may assign this Software License in connection with the sale or other transfer of
the Instrument, provided, that the transferee agrees in writing to be bound by the terms of
this Software License. Except as authorized by the preceding sentence, the User shall not
assign or otherwise transfer the Software or this Software License to anyone, including any
parent, subsidiaries, affiliated entities or third Parties, or as part of the sale of any portion of
its business, or pursuant to any merger, consolidation or reorganization, without SKF CMC­Fort Collins (formerly Baker Instrument Company)’s prior written consent. Any assignment
or transfer effected in violation of this Section 8 shall be void ab initio and of no force or
effect.

9. General

The validity and interpretation of this Software License shall be governed by Colorado Law
except as to copyright and other proprietary matters, which may be preempted by United
States laws and international treaties. In the event of any violation of this Software License,
SKF reserves the right to pursue any state law remedies (including contractual remedies) or
remedies under federal laws or both. The User consents to exclusive jurisdiction in either
state or federal courts in Colorado or both as appropriate and agrees that the prevailing party
shall be entitled to its attorney fees and costs. No decision, act or inaction of SKF CMC-Fort
Collins (formerly Baker Instrument Company), shall be construed to be a waiver of any right
or remedy, and pursuit of any state or federal causes shall not be deemed an election or
remedies. In the event of any provision of this Software License shall be deemed
unenforceable, or void, or invalid, such provision shall be modified so as to make it valid and
enforceable and as so modified the entire agreement shall remain in full force and effect.
This Software License sets forth the entire understanding and agreement between the

vi Dynamic Motor Analyzer—EXP4000 User Manual

Notices

parties and no written or oral representative of any kind whatsoever shall in any way modify
or expand the terms of this User Manual.

In the event of any conflict or inconsistency between the terms of this Software License and
any Documentation, this agreement shall preempt such documentation to the extent
inconsistent.

Important notice concerning warranty and repairs

The warranty is void if (i) the UNIT is shipped without shock absorbing packing material, (ii)
the UNIT is damaged by improper use, (iii) any party other than SKF modifies the Software or
loads or operates unauthorized software programs on the UNIT, or (iv) the User has breached
the Software License set forth above. The User assumes all responsibility and expense for
removal, reinstallation, freight, or on-site service charges in connection with the foregoing
remedies.

SKF CMC-Fort Collins (formerly Baker Instrument Company)’s liability to purchaser relating to
the product whether in contract or in part arising out of warranties, representations,
instructions, installations, or defects from any cause, shall be limited exclusively to correcting
the product and under the conditions as aforesaid.

If the UNIT fails, whether it is under warranty or not, call the SKF service department before
returning the unit for repair. If the unit needs in-house repair, our service staff might direct
you to ship the unit to the authorized service center closest to you. This might save both time
and money. When calling the Baker service department or one of the service centers, please
have the model and serial numbers available. These numbers are located on the rear of the
instrument. If the unit is out of warranty, a purchase order will be required if the unit is
returned for repair.

Virus alert

The UNIT contains computer software that is vulnerable to damage from computer viruses.
Before shipping, SKF scanned all data to ensure the UNIT is virus-free. Before inserting any
disks into the disk drive or connecting the UNIT to a computer network, scan all disks for
viruses.

Trademarks

All other trademarks, service marks or registered trademarks appearing in this manual are
the trademarks, service marks or registered trademarks of their respective owners.

Dynamic Motor Analyzer—EXP4000 User Manual vii

Notices

viii Dynamic Motor Analyzer—EXP4000 User Manual

Table of contents

1 About this manual 1

Formatting ............................................................................................................................ 1

Information devices .............................................................................................................. 1

2 Safety and general operating information 3

General safety precautions ..................................................................................................3

Symbols and labels used on equipment ............................................................................ 3

Safety warnings .................................................................................................................... 4

Operational safety warnings ................................................................................................ 5

Accessory interconnection and use .................................................................................... 5

Cleaning and decontamination............................................................................................ 5

Installation requirements ..................................................................................................... 6

Environment conditions/storage ......................................................................................... 6

Unpacking the unit ................................................................................................................6

Shipping the unit ...................................................................................................................6

3 Getting started 7

Configuring software for motor data .................................................................................. 7

Database features ................................................................................................................ 7

EXP4000 software-specific features ................................................................................. 7

Starting the software ........................................................................................................... 8

Test domain buttons ...........................................................................................................10

Results panels and windows .............................................................................................10

Machine tree ........................................................................................................................12

Keyboard shortcuts .............................................................................................................13

Software tips .......................................................................................................................13

4 Connecting the EXP4000 15

Physical setup of EXP4000 with portable sensors .........................................................15

EXP4000 connections to motor terminals ......................................................................16

Connection Setup window .................................................................................................16

Manual phasor adjustments .............................................................................................. 18

5 EXP4000 tests 19

Test domains and testing theory .......................................................................................19

Power Quality domain ........................................................................................................20

Harmonics ...........................................................................................................................25

Table of Contents

Machine Performance domain ..........................................................................................26

Current domain ...................................................................................................................31

Spectrum domain ...............................................................................................................33

Torque domain ....................................................................................................................37

Connection domain .............................................................................................................40

6 EXP4000 software overview 43

File menu .............................................................................................................................43

Summary Report ................................................................................................................45

Machine menu.....................................................................................................................46

Thresholds menu ...............................................................................................................51

Tools menu ..........................................................................................................................54

Help menu ...........................................................................................................................64

7 VFD4000 analysis software option 65

Operation details .................................................................................................................65

Waveforms ...........................................................................................................................66

VFD Details domain ............................................................................................................67

8 Continuous Monitoring Software option 69

File menu .............................................................................................................................70

Machine menu.....................................................................................................................70

Tools menu ..........................................................................................................................70

View menu ...........................................................................................................................71

Options menu ......................................................................................................................72

General operation icons .....................................................................................................73

Modifying the continuous monitoring tool .......................................................................74

Channel descriptions ..........................................................................................................77

9 Vibration software option 79

Viewing results .................................................................................................................... 82

Tools to enhance viewing graphs ......................................................................................89

10 DC4000 software overview 91

DC4000 Machine Dynamic Analysis software tests and features ................................91

DC4000 Machine Dynamic Analysis software problem types identified .....................91

DC connections for the EXP4000 portable sensors .......................................................92

DC4000 software navigation and overview ....................................................................94

Software testing screen .................................................................................................. 105

Test domains ................................................................................................................... 108

x Dynamic Motor Analyzer—EXP4000 User Manual

Table of Contents

Drive domain .................................................................................................................... 109

Machine domain............................................................................................................... 116

Load ................................................................................................................................... 121

Torque ripple ..................................................................................................................... 122

Load level ......................................................................................................................... 123

Waveforms ........................................................................................................................ 124

Spectrum .......................................................................................................................... 125

Harmonics ........................................................................................................................ 128

Reports .............................................................................................................................. 129

11 Example test and report generation 131

Motor monitoring ........................................................................................................... 131

Looking at data collected ................................................................................................. 132

Creating reports from the report generator ................................................................. 135

Automatic generation of reports .................................................................................... 136

Appendix A — Default settings 137

Default settings ................................................................................................................ 137

Appendix B — Connection troubleshooting 139

General .............................................................................................................................. 139

Non-VFD mode ................................................................................................................ 139

Frequently asked questions ............................................................................................ 140

Appendix C — Blue results 143

Appendix D — EP4000 installation 145

What to do first: ................................................................................................................ 145

Safety precautions for EP installation ........................................................................... 146

Choosing a suitable location for the EP ......................................................................... 147

EP4000 ratings ................................................................................................................ 150

Appendix E — References and glossary 151

Standards .......................................................................................................................... 151

Literature .......................................................................................................................... 151

Glossary of terms ............................................................................................................. 152

Appendix F — Technical specifications 155

Index 159

Dynamic Motor Analyzer—EXP4000 User Manual xi

Table of Contents

xii Dynamic Motor Analyzer—EXP4000 User Manual

1 About this manual

This manual uses the following conventions in formatting, and informational devices to help
you more clearly identify specific elements and information.

Formatting

Interface items are set in Initial Caps and Bold.
Page or window names are set in italics.
File names are set in courier font.

Information devices

Information requiring special attention is set in the following format and structure:

NOTE

Indicates additional information about the related topic that deserves closer
attention or provides a tip for using the product.

NOTICE

Indicates information about product usage that can result in difficulty using
product, a loss of data, or minor equipment damage if not heeded.

CAUTION

Indicates a hazardous situation with potential for minor to moderate injury
or property damage, or moderate to severe damage to the product.

WARNING

Indicates a hazardous situation with risk of serious bodily injury or
death.

About this manual

2 Dynamic Motor Analyzer—EXP4000 User Manual

2 Safety and general operating information

General safety precautions

The general safety information presented here is for operating and service personnel.

NOTICE

If the equipment is used in any manner not specified by SKF the safety
protection provided by the equipment may be impaired.

Symbols and labels used on equipment

Figure 1. EXP 4000 safety labels.

Safety and general operating information

Safety warnings

WARNING

The instrument is not waterproof. Do not allow the opened instrument
to be exposed to water. Water in contact with the interior of the
instrument compromises protection features and could result in serious
injury or death.

Because of the voltages present, testing should be conducted only
by trained personnel. Adequate safety precautions must be taken to
minimize the risk of serious injust, death, or property damage.

Because of the dangerous currents, voltages, and forces encountered
when operating, testing or repairing rotating equipment, safety
precautions must be taken for all tests. Follow all safety precautions in
this manual and required by your employer. Due to the wide diversity
of machine applications, it is impossible to list all general safety
precautions. However, this manual includes special safety precautions
applicable to the use of the EXP4000.

The maximum rating of the EXP4000 is 1,000 V (500 V for DC
operation). 1,000 V (500 V DC operation) is the maximum allowable
voltage between any two of the three voltages and the ground clip.
Under no circumstances connect the voltage sensing circuit to higher
voltage levels. Doing so will cause severe damage to instrument and
can seriously injure you.

4 Dynamic Motor Analyzer—EXP4000 User Manual

Safety and general operating information

Operational safety warnings

Any operator of this unit must comply with the following safety precautions:

• Comply with your facility’s safety practices at all times.

• Ensure physical setup does not interfere with your facility’s current or intended
operation.

Additionally, operators of this unit must adhere to the following safety precautions to
minimize the potential for any dangerous shock hazard conditions:

• Use whatever safety equipment required by your organization, including eye
protection, high voltage gloves, arc-flash rated masks, hoods and any required PPC.
Prior to opening any Motor Control Cabinet (MCC), ensure that appropriate arc-flash
protection clothing is worn.

• Ensure that appropriate lockout / tag-out procedures are properly understood and
implemented by all personnel.

• Every connection at MCC must be performed ONLY when rotating system is powered
down or off.

• Depending on the kind of test to be run, ensure no one is in close physical proximity
to the shaft of the motor or any other moving part of the machinery.

• Do not position motor phase connections near ground or near each other.

• Do not touch the connections, PT’s, CT’s or any component under test while a test is
being made.

• This product is grounded through the grounding conductor of the power cord if
running on AC power.

• Voltage ground clip must be connected to ground when the unit is running on
battery power.

• If you will be running the unit on battery power, ensure that you remove the power
cord from the wall outlet and the unit before using.

• Do not coil power cord or test leads near motor leads.

• During repairs, do not substitute any parts. Use only factory-supplied parts.

• This instrument is NOT approved for use in an explosive environment.

Accessory interconnection and use

Several accessories are available for the EXP4000. These accessories are listed in following
chapters in the manual. They are to be used only as directed.

Cleaning and decontamination

The EXP4000 should be kept clean and in a dry environment. To clean the unit, wipe with a
clean, water-dampened cloth. Do not submerge in water or other cleaners or solvents. To
clean the screen, take a soft, water-dampened cloth and gently wipe the surface.

Dynamic Motor Analyzer—EXP4000 User Manual 5

Safety and general operating information

Installation requirements

The unit may be operated flat on its bottom with the lid open. There are no ventilation
requirements.

The unit is intended for use in Installation Category II (Portable Equipment), Measurement
Category III areas ,and pollution Degree II Environments where occasional non-conducting
condensing pollution can be encountered.

Power requirements
Using the provided AC power cord, connect the unit to a grounded AC power source. The

unit’s power requirements are 100-240 V AC, 50-60 Hz, 3 A AC maximum current draw.

Environment conditions/storage

The unit is designed for indoor use. If used outdoors, the unit must be protected from rain,
snow and other contaminants. Store instrument inside in order to avoid water
contamination.

The unit has been tested for use up to 2,000 m altitude.
The tester should only be operated in temperatures ranging from 41 to 104 degrees

Fahrenheit (5° C to 40° C). This unit is for use at a maximum relative humidity of 80% for
temperatures up to 31 °C decreasing linearly to 50% relative humidity at 40°C.

Unpacking the unit

Carefully remove the following items from the shipping boxes.

• EXP4000

• Power cord

• C Ts

• PTs

• Cabling

• User manual

Shipping the unit

The EXP4000 is shipped in factory foam-filled containers. Should the tester need to be
returned to SKF, we recommend using the unit’s original packaging or any equivalent casing
that meets the following specifications:

• Corrugated cardboard package containers, double-walled, with a minimum burst
test of 275 pounds per square inch and,

• Two to three inches of shock-absorbent material surrounding the entire unit.

NOTE

Cardboard, newspapers, and similar materials are not considered good shock
absorbers.

6 Dynamic Motor Analyzer—EXP4000 User Manual

3 Getting started

Configuring software for motor data

Database management

Database management is highly important in a good predictive maintenance program. It
facilitates organization of periodic maintenance data. The database section of the EXP4000
software allows the entry of identifications to help clarify the location of specific motors. It
can maintain multiple databases for organization of overall program maintenance. For
example, if a facility has two buildings with a number of motor sights in each, it may work
best if there were a database created for each building.

Consequences of not organizing data into databases

Since the EXP4000 can be configured to store every test it ever performs, an organized
structure is needed to facilitate data integrity and usefulness. Also, creating multiple
databases allows easier management of file size and archiving.

Plant maintenance

It is common for plants to have duplicate processes, with identically named motors in each
process. (ex: intake pump) This can cause confusion, since the motors are in different
locations, but have the same motor ID. Take steps to make motor ID’s unique.

For example, the motor ID for process 1 should be intake pump P1 while the motor ID for
process 2 should be intake pump P2.

Database features

The records that are stored by the EXP4000 are linked to each other hierarchically. The
principle record, which serves as the base for linking associated records, is the machine ID.
Information entered into machine ID and test ID records become part of the database. Like
other database information, it can be transferred to other computer programs or other
computers.

Navigating the software interface

Familiarity with Windows 98se®, Windows NT SP4®, Windows 2000®, Windows XP®, or
Windows 7® and basic computer skills is assumed. Working with the EXP4000 software
requires a general understanding of using multiple windows, a variety of keyboard
commands, and a pointer device (mouse).

EXP4000 software-specific features

Grey-shaded fields

Gray-shaded fields are generally not editable. Fields with white backgrounds are editable.

Text fields

Text fields are areas that contain editable words or numbers. To edit text fields, press or click
in them and type. The software will prompted you for missing information required by the

Getting started

EXP4000 if a necessary field is left blank. This is generally seen when creating or editing
motor or machine properties.

Arrows and windows icons

In the EXP4000, arrows serve two functions. They allow you to access information that does
not fit on the screen or they allow you to change numbers in a text field. For example,
clicking on either the up or down arrow can change a caution threshold for the voltage
unbalance test in an electrical test model.

Numeric fields

The two types of numeric fields are input and display. The input fields are required to
calculate portion of the result panels or allow entering additional information to the reports.
All other numeric fields are display results.

Starting the software

1) To start the EXP4000 software, click on the Explorer icon on the desktop or click on
Start-> All Programs-> Explorer-> Explorer. The Explorer main window appears

as shown below.

Figure 1. EXP4000 user interface.

2) When you click on File in the Main toolbar then select a database, the Machine tree
populates as shown in the example above.

3) Clicking on a machine in the list populates the rest of the interface as shown.

8 Dynamic Motor Analyzer—EXP4000 User Manual

Getting started

• The Main toolbar, located a the top of the interface, provides the primary controls
for access to test and machine information, along with tools used to conduct tests.

• The Machine information bar identifies the current motor or device under test
along with the basic nameplate information for the machine.

• The Waveform display provides the primary graphical representation of the
waveforms saved for the related measurement. The voltage waveform display can
be set to Line to Line or Line to Ground mode via the Options Display tab under the
Tools menu.

• The Test domain buttons provide access to specific test results and indicate the
status of test results.

• The Torque time/speed display shows the torque/time measurement acquired in
VFD operation mode or the torque/speed measurement acquired in line operation
mode.

• The Display phasor icon open a new window showing the Phasor diagram for the
related machine.

• Numerical display fields to the left of the Waveform display provide measurements
collected for the single phase to neutral voltages or line-to-line voltages (depending
on the setting in the Tools Options menu), single-phase currents, average, power
factors, average current, total electrical input power and average line-to-line
voltage. These fields include:

– Voltage [V]—average line-to-line voltage.
– Current [A]—average line current.
– PF—power factor.
– V Unbal [%]—voltage unbalance percentage.
– I Unbal [%]—current unbalance percentage.

• Numerical display fields to the right of the Torque time/speed display provide
measurements collected for the motor’s mechanical and electromechanical
operating condition. These fields include:

– Efficiency [%]—efficiency percentage
– Torque [ft-lb]—motor torque in foot-pounds (or Nm if set to metric).
– Load [%]—percent load to the motor under test.
– Load [hp]—energy load to the motor under test.
– Speed [RPM]—speed of the motor.

• Sensor—portable (internal) or EP (external).

• CTs—current rating of the CTs.

• Auto-Phase—used during line operation to set up the line and current inputs.

• Test date/time dropdown menu and controls— This text field displays the time of the
current and previous test data.

NOTE

Pressing the [F1] key on your keyboard opens context help for the window.

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Getting started

Test domain buttons

Each test domain button provides access to its specific test results.
Because each threshold equates to a specific color, the software assigns a color to the

domain and the testing domain buttons depending on the test result. For example, if the
result of the voltage unbalance test falls below the established caution thresholds, the
software would assign the color green to the voltage unbalance button.

Results panels and windows

Clicking on any of the test domains opens a test results panel that you can use to select test
results to display in a window like the one shown in the example below.

Figure 2. Selecting test results to display using Results panels.

The contents of the results dialog box varies depending on the related test type. Many
include two tabs—Result and Trend—as shown in the example above.

Result tab

In this example of the Result tab, we see three main sections.
The Measurement display indicates the severity of the test results compared to the

threshold indicators.

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Getting started

The Threshold bars display the current threshold level. The threshold is user specified in the
electric or vibration models. Each bar has an associated color level:

• Red = warning

• Yellow = caution

• Green = good

• Blue = no applicable threshold
The numeric display in the lower panel presents relevant test result data such as the NEMA

percentage derating factor, the percentage load, and amplitudes for the voltage phasors.

Trend tab

The Trend tab displays trending data for the relevant test. It displays the value of the
monitored quantity (y-axis) against the test numbers (x-axis). The x-axis shows the number
of measurements performed for that particular motor ID.

Figure 3. Trend tab.

The Trend tab allows you to access specific test results by clicking and holding the left mouse
button on the marker and dragging it to a new location. Each test result contains the date
and time for the test and important numeric results, which will change to display the new
test results data when you release the mouse button.

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Getting started

Machine tree

The left panel in the main user interface window is the Machine tree. The highest level is
the database name (depicted by a file cabinet icon). Folders are used below each database
to store machine test data or other folders. In turn, machines are stored within the folders.

1) Use the plus and minus icons to the left of tree elements to locate the machine that
you want to test.

2) Click on the target machine to highlight it. Its name and related nameplate
information will appear in the Machine information bar just to the right.

3) Ensure that the EXP4000 is properly connected to the machine.

4) Press Run Electrical to start testing and data collection.

5) Alternatively, you can click on the Tools menu then the Run Electrical item.

Figure 4. Machine tree used to find files and folders for testing.

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Getting started

Upgrading databases from previous software versions

Before the EXP4000 software can open a database from previous versions of the software, it
must upgrade the database. This upgrade tool will pop up whenever you open a database
that can be upgraded. It will place the file in a default directory. This directory must be a
separate database from the one where existing data is stored. After the database is
upgraded, it will automatically open in the software.

NOTICE

Upgrading a database does not delete the old database. It allows
expanded capabilities within the new software to be used, while permitting
the use of older versions of software on the old database.

An application is available to automatically update all databases at once. Contact CMC-Fort
Collins support for information on obtaining and using this application.

Keyboard shortcuts

• F1 key on the keyboard opens the loaded Help environment.

• F2 key opens the machine properties.

• F3 key operates the New AC Machine function.

• F5 key operates the Run Electrical function.

• F7 key opens the Virtual Scope feature.

• F8 key displays the View Connections function.

• F9 key operates the Transient Analysis Dialog

• Ctrl A – About

• Ctrl M – User Manual

• Ctrl O – Open Database

• Ctrl N – New Database

Software tips

Popup panels require you to immediately interact with dialogs that affect displayed data
(loaded or part of a test).

The time required to load a machine with a large number of tests has been decreased by
internally connecting or threading the test logs.

When the machine is loaded, but the thread is not completed the message “Test log is
Loading” appears instead of the test log graphs. This can cause a perceived lag if you quickly
switch machines or delete test results from motors with more than 100 stored tests. This lag
time will also be noticeable if you load a machine with a large number of tests and then exit.

At this publishing, we recommend keeping the number of tests per motor to a maximum of

2000.

Dynamic Motor Analyzer—EXP4000 User Manual 13

Getting started

14 Dynamic Motor Analyzer—EXP4000 User Manual

4 Connecting the EXP4000

NOTICE

Ensure that all safety warning and procedures have been read and are
understood before proceeding with any setup process.
Refer to the “Safety and general operating information” chapter for details.

WARNING

For all connection procedures: to minimize risk of injury or death from
electric shock, make sure the motor iis turned off before opening panels
or making connections.

NOTE

Make sure the current direction arrow points in the direction of the load when
connecting current clamp-ons. Voltage clip-ons and current clamp-ons should be
connected to the cold side of the breakers.

Physical setup of EXP4000 with portable sensors

1) Connect the marked voltage clip-ons to the voltage port on the EXP4000.

2) Connect the marked current clamp-ons to the current signal port on the EXP4000.

3) Turn on power to the laptop.

4) Double click the EXP4000 icon to start the program.

Connecting the EXP4000 to the MCC

1) Open the panel of the MCC.

2) Connect a voltage clip-on to each phase of the breaker.

3) Attach one current clamp-on per phase.
Both the current and the voltage sensors of the EXP4000 are designed for low voltage. AC

voltage sensors are rated for 1000 VAC. DC voltage sensors are rated for 500 VDC Attach
Hall Effect CTs and DC Voltage Sensors for DC Motor testing applications. In order to measure
medium or high voltage motors, additional CTs and PTs are required. In this case, the current
clamp-ons and voltage clip-ons have to be connected to the CTs and PTs on your site.

4) The voltage clip-ons and current clamp-ons should match color-wise on each phase.
Ex. The yellow voltage clip-on should be attached to the same phase as the yellow
current clamp-on.

Connecting the EXP4000

EXP4000 connections to motor terminals

1) Connect the current clamp-ons and voltage clip-ons to the terminal box.

2) The voltage clip-ons and current clamp-ons should match color-wise on each
phase; for example, the yellow voltage clip-on should be attached to the same phase
as the yellow current clamp-on.

3) Attach one voltage sensor to each phase.

4) Exercise extreme caution to make sure that no terminals or clip-ons touch each
other or touch ground when energized.

5) Prior to energizing the motor, exercise extreme caution to make sure that no
terminals or clip-ons touch each other or touch ground. Energize the motor.

Physical setup of the EXP4000 with EPs

See Appendix D for installation instructions for EPs.

1) Connect the EXP4000 end of the mixed AD cable to the MCC port on the EXP4000.

2) Connect the other end of the mixed AD cable to the MCC plug.

3) Set the Sensors option of the main panel to EP.

4) Click on Run Electrical.

Connection Setup window

When performing an electrical test on a line operated motor, one of two warnings can
appear. The first warning will appear if the Auto-Phase feature is not activated (box checked
in the main window), and the EXP4000 realizes that the connection is mistaken (for example,
having the current and voltage connections being in acb and abc sequence, respectively).
The second warning will appear if Auto-Phase has failed due to excessive unbalances on the
measured currents or voltages. This can be from lacking one voltage signal, not having
properly closed a CT.

Clicking on Yes will take you into the connection setup wizard. Clicking on Continue Test will
continue testing using the physical setup. Clicking on Abort Test will stop the test without
saving any information to the database.

Setup wizard/suggest button

Figure 5. Connection Setup window showing Suggest button.

When the connection setup wizard appears the Suggest button is available. The Suggest
button’s purpose is to offer reasonable solutions in error mitigation. If there is more that one

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Connecting the EXP4000

realistic solution, you will be prompted about load level. A selection of a high load scenario
(90% and higher) or a low load scenario (20% and lower) can be made. This dialog rarely
pops up.

NOTE

This high load and low load scenario may be an indication of incorrectly entered
nameplate data.

Two-CT solution

The two-CT solution is based on Kirchhoff’s law of currents: The sum of currents into a node
is equal to zero, Ia+Ib+Ic+Ig=0.

NOTE

Calculating the current of the third phase is only valid while there is no noticeable
ground current (Ig=0). This is typically the case; however, a high impedance ground
system with one grounded phase is an exception.

A two-CT setup is needed if you are physically unable to connect all three CTs, or if all three
CTs are connected, but one did not close or it is connected to a wrong wire. If two or more
CTs are not connected then the test should be aborted and the CTs manually adjusted.

In the example below, the blue CT is disconnected and an electrical test is performed. Notice
that the amplitude is zero.

If the CT is not totally closed the phasor will be greater than zero, but noticeably less than the
other CTs.

Figure 6. Connection Setup window indicating connections need to be checked.

Figure 7. Connection Setup window indicating connection are good.

Dynamic Motor Analyzer—EXP4000 User Manual 17

Connecting the EXP4000

Manual phasor adjustments

Manually adjusting the phasors can quickly become confusing. If the Suggest button does
not provide a solution, or if there is not a unique setup, then manually adjusting the phasors
might be necessary.

Adjustments are exactly the same as those made in the MCC when properly connecting the
EXP4000. There are two rules for adjusting phasors:

1) All Phasors (currents and voltages) should have an angle between them of 120
degrees ± 5.

2) For all induction motors, the current phasor must follow the voltage phasor by a
maximum of 90 degrees.

The graphic below illustrates all phasor positions. All three current phasors must be in the
same area in order for the setup to be correct. For example if the Ia phasor is in the high load
position, Ib and Ic must also be in the high load position. The dark shaded are non-phasor
positions. Although this can be done mathematically, phasors cannot physically reside in the
dark shaded areas (three phase induction motors) without PF correcting devices.

Figure 8. Phasor diagram.

There is the possibility that phasors can reside in the high load position or be rotated 180
degrees and be in the low load position. In order to minimize potential errors, we have
provided a load estimate. If the phasors are setup in the high load position and the load
estimate is 300 percent or higher, then the most likely correct solution is to rotate the phasors
to the low load position.

NOTE

To go from a high-load position to a low-load position, rotate each dial one position
to the left. To go from a low load position to a high load position: rotate each dial to
the right one position.

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5 EXP4000 tests

Test domains and testing theory

The EXP4000 utilizes a multitude of tests to determine the power condition, health, load, and
energy profile of machines.

The following test domains describe the functionality of the instrument along with a
description of each test.

Testing capabilities

The EXP4000 is equipped with standard software to initiate testing. Additional software can
be purchased if necessary to complete the program you deems necessary. This additional
software is explained in chapters later in this manual. The standard software includes the
following domains and tests:

• Power Quality: Voltage Level, Voltage Unbalance, Harmonic Distortion, Total
Distortion, Power, Harmonics

• Machine Performance: Effective Service Factor, Load, Operating Condition,
Efficiency, Payback Period

• Current: Over Current, Current Unbalances

• Spectrum: Rotor bar, V/I Spectrum, Harmonics

• Connection: Waveforms, ABC/SYM Comp., Phasors

To view any of these tests, click on the associated domain and then on the associated test.
Many of these viewable panels will have results and test log views.

Each domain test window includes a Result tab and a Trend tab. The Result tab displays
results of the current test. The Trend tab graphically displays the current test results along
with previous test results.

EXP4000 tests

Power Quality domain

Voltage Level

• Identifies over- and under-voltage conditions.

• Compares measured voltage levels with user-defined thresholds.

Figure 9. Voltage level test within the Power Quality domain.

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EXP4000 tests

Voltage Unbalance

• Examines the single-phase voltage in the motor by calculating its percentage
unbalance via NEMA derating.

• Compares the voltage unbalance level with the stored threshold.

• An unbalanced voltage condition causes negative sequence currents within the
stator, resulting in excessive heat. The voltage unbalance test determines if an
unbalanced voltage condition exists in the machine. The EXP4000 utilizes the
NEMA derating curve that specifies a maximal load for each type of unbalance.

Figure 10. Voltage unbalance within the Power Quality domain.

NOTE

The value in the NEMA Derating field will equal 1 unless there is voltage unbalance
and 5,7,11,13 order voltage harmonics are present.

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EXP4000 tests

Harmonic Distortion

The harmonic distortion function examines the total harmonic distortion of the three single
phases to neutral voltages. It compares the level of total harmonic distortion to the threshold
values that you define.

Figure 11. Harmonic distortion.

Stator current, torque, and operating speed typically describe the health of a machine. For
example, maintenance personnel should be alerted if a machine needs to run at a lower
speed in order to provide the same torque. The machine may have an issue caused by
broken rotor bars, excessive heat, or varying voltage conditions.

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EXP4000 tests

Total Distortion

Both Total Harmonic Distortion (THD) and Total Distortion (TD) deal with quantifying the
effect of nonfundamental components to the voltage and current waveform. Whereas the
Harmonic Distortion focuses on the harmonic content alone, Total Distortion focuses on all
nonfundamental components.

Figure 12. Total distortion within the Power Quality domain.

The commonalities and differences between THD and TD are:

• THD adds only harmonic components and divides by the fundamental.

• TD subtracts the fundamental from the RMS and divides by the fundamental.

• THD is defined in IEEE and NEMA standard, whereas, TD is not defined in these
standards.

• THD delivers reliable results for line-operated machines.

• TD delivers reliable results for all machines.

• For all applications, TD values must always result in higher values than THD.

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EXP4000 tests

Power

The Power window provides information to define power qualities for each phase along with
the average / sum values.

The window has five major sections.
The first section displays kilowatts (kW), kilovolt amperes (kVAr), and kilvolt amperes (kVA).
The next section displays the power factor (PF), voltage (V), and current (I) values.
Total harmonic distortion voltage (THD V) and total harmonic distortion current (THD I) are

presented in the third section.
The crest factor voltage (Cf V) and crest factor current (Cf I) values are shown in the fourth

section.
The voltage unbalance percentage, current unbalance percentage, and frequency are

presented in the last section.

Figure 13. Power data displayed within the Power Quality domain.

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EXP4000 tests

Harmonics

The Harmonic components compare the magnitude of the harmonic components to the
fundamental currents and voltages of the system. The bar chart displays the distribution of
the harmonic content on the different frequency bands for all currents and voltages.

Figure 14. Harmonics within the Power Quality domain.

1) Select the voltage and current channels that you want to display by checking the
boxes next to the desired channels in the Select Channels section.

2) Adjust the harmonics range that you want to displayed by using the From and To
combo boxes found in the Show Harmonics section.

3) Click on the Export button to export the data collected to a comma separate values
(.CSV) file.

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EXP4000 tests

Machine Performance domain

Effective Service Factor

• Graphically displays the estimated percentage load derated with the NEMA derating
factor,

The Effective Service Factor test identifies how closely the motor is operating to its effective
service factor. The test predicts heat-based deterioration and provides an accurate thermal
assessment of the motor.

Figure 15. Effective Service Factor within the Machine Performance domain.

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EXP4000 tests

Load

This displays the estimated load for the machine, and compares it with defined thresholds. A
100% threshold is commonly used since operating above that level may rapidly thermally
deteriorate the machine. However, a combination of environmental conditions and criticality
of the machine may warrant moving the threshold level to a higher or lower value. For
example, additional cooling of the machine may be a reason for allowing a higher load level
prior to issuing an alarm.

Figure 16. Load test within the Machine Performance domain.

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EXP4000 tests

Operating condition (OpCond)

Each induction motor has a torque-speed and current-speed characteristic operation curve.
These curves will vary their signature if an induction motor’s operation changes from healthy
to a faulted condition. For example, increased operation temperature, fluctuating
environmental conditions, varied power supply conditions, or broken rotor cages can alter a
motor’s operating condition.

Differences in operating condition could indicate two things:

• a change in the operating process, or

• a condition that may influence the motor’s operation.

A resultant warning does not necessarily imply a defect in the machine, load or power supply.
However, it is important to monitor the machine’s operating condition. Any identifiable
changes could affect the future operation of the motor.

Figure 17. Operating condition test within the Machine Performance domain.

Efficiency

Efficiency is the ratio of the mechanical output of the motor’s power to the electrical input
power to the motor.

Where:
Ploss = the power that dissipates (mainly heat)
Pin = input power
Ploss can bee seen as potential energy waste in the power bill and it degrades motor health.

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EXP4000 tests

The efficiency test displays the motor’s operating efficiency and previously measured motor
efficiencies. Low results in the efficiency test suggest that motor retrofits may be advisable.
A decline in efficiency may indicate an increase in the motor’s operating temperature, causing
faster motor degradation.

A manufacturer database with more than 20,000 different motor designs is provided. This
database compares existing motors with similar designs that perform at or above EPAct’92.
These motors are compared with respect to current operating load point, and their resulting
efficiencies. If the efficiency of the motor under test is significantly lower than the target
efficiency found on a EPAct motor, a warning or caution flag is issued.

If an efficiency warning or caution flag is issued, the following steps should be taken:

1) Check that the correct stator and lead line-to-line resistances have been entered into
the Create Motor or Edit Motor panels in the EXP4000 software.

2) Motors can operate at low efficiencies because of their design, or poor power
conditions. Check that the voltage level is appropriate for the motor tested. Make
sure voltage unbalance and voltage distortion are acceptable.

NOTE

To ensure the accuracy of the efficiency estimation, the correct stator resistance
must be entered for the motor when the new AC machine is created.

Figure 18. Efficiency test within the Machine Performance domain.

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EXP4000 tests

Payback period

This test searches the database for motors, and compares the energy expenses of the motor
under test with higher efficiency motors. Payback period is calculated, based on the
compared motor’s list price, the energy savings calculated according to the specified duty
cycle of the motor, the entered $/kWh, and the latest calculated input power of the motor.
This test uses the premise that the comparison motor operates, on average, on a load point
similar to the one measured. All prices are in USD, so the energy costs have to be specified in
USD. List prices are motor manufacturers’ data, and are based upon the U.S. market. If the
EXP4000 is used in countries outside of the U.S., the list price should be adjusted accordingly.

Figure 19. Payback period within the Machine Performance domain.

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EXP4000 tests

Current domain

Current Level

The current level function compares the single-phase current with the stator current listed on
the tested motor’s nameplate. Too much current can overstress particular phases in the
machine. The current level test determines if the machine might be drawing more than its
rated current on one or more phases. This causes excessive heat and decreasing life of the
insulation.

Figure 20. Current level test within the Current domain.

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EXP4000 tests

Current Unbalance

Unbalanced currents are frequently caused by unbalanced voltages. A common rule of
thumb is that voltage unbalance can be the cause of up to eight times larger current
unbalances. Machines will also show very large current unbalances under very light, or no
load conditions—even when driven by a balanced voltage. These no-load current unbalances
are common in healthy machines, and they vanish rapidly when the machine is loaded.

Figure 21. Current unbalances within the Current domain.

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EXP4000 tests

Spectrum domain

Rotor Bar

The rotor bar function records the relative amplitude of the rotor-bar sideband, and
compares the rotor cage signature to stored thresholds.

Figure 22. Rotor bar within the Spectrum domain.

The rotor bar test evaluates the overall condition of the machine. Broken rotor bars cause
excess heat on the machine, decreasing efficiency, shortening insulation life, and possibly
causing core damage.

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EXP4000 tests

V/I Spectrum

The V/I Spectrum window analyzes the frequency spectra of the three line-to-neutral voltage
waveforms and the three line currents independently of each other. The current spectra have
shown to contain information related to the vibration spectra of the machine; roller-bearing
faults can be identified by using the frequency marker controls on the lower left. The feature
can also help you find deteriorating alignment problems, load unbalances, looseness,
eccentricity, and cavitation by analyzing these spectra.

Figure 23. V/I spectrum within the Spectrum domain.

You can zoom in on (enlarge) specific regions on the graph by clicking and holding the left
mouse button and dragging your mouse cursor to select the desired area to enlarge. More
information about how to zoom can be found by clicking on the Zoom Info item in the toolbar
at the top of the window.

V/I Spectrum graphs also have a Graph Options item in the menu bar, which you can use to
define masking preferences of the electrical frequencies. In addition, the width of the mask (in
Hertz) can be defined.

Just below the Zoom Info menu, you will see two icons. The first one allow you to export the
spectra data to a spreadsheet. The second icon enables the display of time waveform data
below the spectrum graph.

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EXP4000 tests

Demodulated Spectrum (option)

Available with the purchase of the T4000 Torque analysis software option, the Demodulated
spectrum feature calculates the three-dimensional demodulated spectrum of the torque
signature. With the channel control, this signal can be changed from torque to current or
voltage of any one of the phases. The demodulated spectra tool analyzes the dynamic
behavior profile of the motor load system.

Figure 24. Demodulation Spectra window elements.

The main information of the Demodulated Spectra window is the three-dimensional
demodulated spectrum graphic and the frequency of spectrum graph.

The Marker can be moved by a simple drag-and-drop operation.

1) Hover the mouse cursor above the marker, which changes to a pointing finger.

2) Click on hold down the left mouse button then move the cursor to the new point of
interest and release the button.

The marker’s location determines the projections plotted on the Frequency of spectrum and
Band projection graphs. It shows the relative amplitudes of the frequency for the different
bands of AM demodulation.

The Frequency scale at the bottom of the three-dimensional graph has the same meaning as
the scale below the projection. Typically, frequency components of interest are read on these
scales.

The Channel selector position determines the demodulation algorithm that needs to be run
for voltage or current of the phases (A, B, or C), or over the default torque setting. The graph
amplitude is displayed in volts, amps, or Newton meters.

The Frequency Range setting allows for zooming in or out on the display.
The Band scale identifies the different AM demodulation bands that have been analyzed via

the DFLL.
The Viewing controls change the three-dimensional graph settings. Disabling the Projection

Only view and enabling the Zoom/Rotate options allows changes to viewing the three-
dimensional graph. The particular keys for zooming, panning and restoring, are described in
the Zoom Info link found in the top left corner of the window.

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EXP4000 tests

Harmonics

The Harmonic components compare the magnitude of the harmonic components to the
fundamental currents and voltages of the system. Bar charts display the distribution of the
harmonic content on the different frequency bands for all currents and voltages.

Figure 25. Harmonics within the Spectrum domain.

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EXP4000 tests

Torque domain

Also made available with the purchase of the T4000 torque analysis software option is access
to the Torque testing domain, which provides access to the Torque Ripple and Torque
Spectrum testing features.

Torque Ripple Results tab

The Torque Ripple window has two tabs: Results and Trend. The Results tab shows the
measured torque over time compared to the rated torque calculated from the motor
nameplate information.

Figure 26. Torque Ripple window—Results tab— within the Torque domain.

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EXP4000 tests

Torque Ripple Trend tab

The Trend tab shows a graphical comparison of the torque results for the current and
previous measurements.

Figure 27. Torque Ripple window—Trend tab—within the Torque domain.

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EXP4000 tests

Torque Spectrum

Clicking on torque spectrum opens a window that shows the frequency spectra of torque. The
Y-scale display units can be set to logarithmic, linear, or decibel.

You can zoom in on (enlarge) specific regions on the graph by clicking and holding the left
mouse button and dragging your mouse cursor to select the desired area to enlarge. More
information about how to zoom can be found by clicking on the Zoom Info item in the toolbar
at the top of the window.

When the new enlarged area is identified using the zoom feature, the software will display
the frequency components of the signal located between the vertical markers.

Markers in the graph can be moved by clicking and holding the left mouse button and
dragging the marker to a desired new location.

This means that the narrower the window between the markers is, the higher the resolution.

Figure 28. Torque Spectra window within Torque domain.

The y-axis scale can be set to either logarithmic, linear or dB. The x-axis can be displayed in
either Hertz or KCPM (1000 CPM).

Frequency markers can be added to display the frequencies of known faults. You can add
bearing markers by clicking the + below the list of available markers. The frequency band can
be changed and allows you to control which harmonic of the fundamental will be used to
mark the frequencies of interest. In torque, fault frequencies will be most prevalent at DC
(Freq. Band 0), other frequency bands can be selected to verify the presence of a fault. Using
the harmonics multiples you can mark N multiples of the frequency of interest and sideband
markers can also be used to examine the haystack around a Nth harmonic.

Data can be exported to CSV format so that in can be easily imported into MS Excel® or
other programs by clicking on the Export Data icon found just below Zoom Info. You can
choose to export Spectrum Data or Time Waveform Data.

The icon to the right of the Export Data icon allows you to toggle time waveforms on or off.
Torque graphs also have a Graph Options item in the menu bar, which you can use to define

masking preferences of the electrical frequencies. In addition, the width of the mask (in
Hertz) can be defined.

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EXP4000 tests

Connection domain

Waveforms

The Waveforms window displays the waveforms for all three current and voltage
measurements for line operated mode. If the EXP4000 is operated in VFD mode (not
available in basic software), it shows the voltage and current measurements for phase A.

Figure 29. Waveforms in the connections domain.

1) Use the dropdown list just above the display area to select how the data will be
displayed: line-to-line or line-to-neutral.

2) The data can be exported to a comma separated values (.csv) file by clicking on the
Export Data icon just to the right of the dropdown list.

3) Zoom in on the graph by pressing and holding the left mouse button and drawing a
rectangle around the area of interest. Zoom characteristics are described in the
Zoom Info menu found just above the display area

4) Checking the boxes below the display area tells the software which measurements it
needs to display. Measurements are color-coded to ease identification.

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EXP4000 tests

Symmetrical Components (Sym. Components)

The Symmetrical Components window displays the voltage, current and impedance
unbalance, the positive sequence (accelerating), and the negative sequence (retarding)
current, voltage, and impedance information.

Figure 30. ABC/SYM Comp within the Connection domain.

Phasors

The Phasors window shows the a,b,c phasors for voltages and the current in line operated
mode.

Figure 31. Phasors within the Connection domain.

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EXP4000 tests

42 Dynamic Motor Analyzer—EXP4000 User Manual

6 EXP4000 software overview

This chapter is intended to convey a general knowledge of how to use and navigate EXP4000
software, with a step-by-step guide through the software menus and procedures for data
collection and management.

File menu

The File menu is used to upload and save motor data files. It includes the following items:
Database, Report Generator, Summary Report, and Exit.

Figure 32. EXP4000 software File menu.

Database

Selecting the Database menu item provides you with options to open an existing database
file, create a new file, or close an existing file.

To create a new database, perform the following steps:

1) Click on the File menu, Database then New.

2) Type the name of the new database in the File name field.

3) Click on the Save button.

To open an existing database, perform the following steps:

1) Click on the File menu, Database then Open.

2) If needed, locate the database in the file structure then click on the database to be
opened. Its name should appear in the File name field.

3) Click on the Open button.

NOTE

Changing databases during operation is allowed by using the preceding procedure.

To close an existing database

1) If multiple databases are open, select the one you want to close.

2) Click on the File menu, Database then Close. This will automatically close the
database.

EXP4000 software overview

Report Generator

The reports section offers the ability to customize reports to see multiple tests with different
filters and trending options.

The Filter On option helps you select good, caution and/or warning results. It also allows you
to select a date range to request specific tests for the report.

The Select options helps you select results via All, All Good, All Caution, All Warning, All
Warning and Caution, or None parameters.

The Trending option provides parameter selection by choosing All Machine Results, Selected
Results Only, and Plot Mode. Plot Mode provides further resolution by allowing you to select

Line or Point + Line.

Figure 33. Select Results dialog for generating reports.

The EXP4000 software generates an .rtf file that can be opened in Microsoft Word®,
WordPad or other word processing programs for editing. Remember that report page count
will increase dramatically with the addition of multiple tests. This can increase time in report
generation and printing.

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EXP4000 software overview

Summary Report

This option will print an overall summary of the testing done for the selected machine test in
the Machine Tree.

Figure 34. Machine Performance Report screen.

These reports options include: Main Panel, Power Condition Report, Machine Condition
Report, Energy Assessment, Machine Performance Report, and Load Reports. These items
will print the panel page for that specific test.

The value in the Location field is determined by the name given to the first-level folder
located in the database the motor resides in. The value in the Building field is determined by
the name given the second-level folder located in the database the motor resides in.

Clicking on the Test Notes item in the Tools menu populates the Memo, Test by, and Test
For fields.

Exit

The Exit menu item closes the program.

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EXP4000 software overview

Machine menu

The Machine menu provides you with the tools to assign, create, edit, or delete particular
motors or other devices to be tested. Under the Machine menu are the following options:
New AC Machine, Machine Properties, Acquire EP Serial Number, and Reset EP Serial
Number.

Figure 35. Machine menu.

New AC Machine

Clicking on the New AC Machine menu item opens a dialog box used to generate a new
machine ID, which is required to run electrical or vibration tests. The Machine Properties
dialog box includes three tabs: Name Plate, Machine Information, and Dynamic Testing.

Fields within the Name Plate and Machine Information tabs appear in red when required
information is needed. All fields in red must be filled with appropriate data before the
software will allow you to continue with the process.

Fields marked in yellow can affect the results the EXP4000 can generate. Remember that
the more information that is accurately entered, the more comprehensive the results will be.
The software prompts you for missed information. The EXP4000 software also includes
IntelliCreate technology, which checks the applicability of entered data. IntelliCreate identifies
the majority of typos and omissions of data fields during machine creation.

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EXP4000 software overview

Name Plate tab

As indicated by the red fields when first opening, data entry is required for nearly all fields in
this tab.

Figure 36. Create Machine Name Plate tab.

1) Click in the Name field and give the motor/device an appropriate name, typically
reflecting the process that it is running.

2) Use the Tab key on your keyboard to move between the fields in the Name Plate tab
and enter values for each required field.

3) Enter values in other fields to provide more resolution and to improve report quality.

4) Some items will be automatically calculated and their values automatically entered
in the appropriate related fields. For example, the corresponding Power Out [kW]
data will be automatically entered to complement the Power Out [hp] entered.

5) Check the VFD box if the motor is being driven by a variable frequency drive device.

6) Continue with the Sensor Rations button instructions if you are connecting to the
secondaries of CTs and PTs; otherwise, proceed with entering data in the Machine
Information tab.

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EXP4000 software overview

Sensor Ratios dialog box

When connecting to the secondaries of CTs and PTs (typically done when working in the field),
click on the Sensor Ratios button to open a dialog box like the one shown below.

Enter the voltage and current ratios as needed, then click on OK.

Figure 37. Sensor Ratios dialog box.

NOTE

This needs to be set up with the ratios of the PTs and CTs whenever a motor is
tested at the low voltage side of PTs and CTs

Machine information tab

The only required element in the Machine Information tab is the machine Name. This will
automatically filled from your entry in the Name Plate tab. The location and building will be
filled in from the default database items. All other information is optional; however, it can be
important for tracking instrumentation and report generation.

After you enter data in this tab, continue with data entry in the Dynamic Testing tab.

Figure 38. Machine Information tab.

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EXP4000 software overview

Dynamic Testing tab

The information entered into the Dynamic Testing tab of the create machine section are
optional items. Remember that the more information that is entered, the more accurate the
results will be.

Figure 39. Dynamic Testing tab.

When an EP has been assigned to a motor, the serial number of the EP will appear in the EP
Serial Number field.

Assigning an EP to a motor

1) From the Tools menu, click on EP, Mode, then Auto Assign.

2) Select the motor in the Machine Tree.

3) Set the main panel Sensor field to “EP.”

4) Connect the EXP 4000 to the EP.

5) From the Machine menu, click on Acquire EP Serial Number.

6) A message dialog will pop up to let you know that the EP was successfully assigned.

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EXP4000 software overview

Machine Properties

Clicking on the Machine Properties menu item opens a the Machine Properties dialog box as
shown below to help you make changes to existing machine information on the machine
selected in the Machine Tree. The same tabs and features used in the process to create new
machines are available. You can add or change data as needed to correct or complete your
information.

Figure 40. Machine Properties dialog box.

Acquire EP Serial Number

When the EXP4000 is connected to an external EP device, clicking on the Acquire EP Serial
Number item permits association of a particular EP with a Motor ID. This will enable the

direct storing of data taken via an EP without the need of selecting the motor prior to testing.
After you click on this menu item, the software checks for the requested information and
notifies you if the procedure was successfully completed.

Reset EP Serial Number

Clicking on the Reset EP Serial Number item disassociates a machine with an EP serial
number so the EP can be re-associated with a newly-installed machine. After you click on
this menu item, the software completes the disassociation and you an then re-associate
another machine with this EP by clicking on the Acquire EP Serial Number item.

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EXP4000 software overview

Thresholds menu

An electrical test model is a set of thresholds used as a guide against which the machines will
be tested. The EXP4000 compares test results with the electrical model’s predetermined
tolerances.

Figure 41. Thresholds Menu

Select Test Model

Clicking on the Select Test Model menu item opens a dialog box like the one shown below,
which you will use to designate the model you will use to test your motors.

Figure 42. Select Test Model dialog box.

1) Click on the Thresholds menu.

2) Click on Select Test Model.

3) Select a test model from the Select Test Model dropdown list.

4) When you find the test model you need, click on it then click on the OK button.

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EXP4000 software overview

Create Test Model

When you click on the Create Test Model item, a new window opens as shown below. You
will use this window to define the thresholds for the test model. This is useful for creating
templates for motors in different service environments.

1) Click on the Thresholds menu.

2) Click on Create Test Model.

3) Type a name for the model in the Test Model Name field.

4) For each test type, enter the caution and warning thresholds. Adjust thresholds by
clicking the up and down arrows or by entering numbers directly in the fields.

NOTE

For the Voltage Level test, enter caution and warning level thresholds for over and
under voltages independently from each other.

5) After you have entered your criteria, click on the Create button. This will save the
new test model and return to the EXP4000 window.

Figure 43. Create Test Model dialog box.

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EXP4000 software overview

Edit Test Model

Clicking on the Edit Test Model menu item re-opens the Select Test Model dialog box so you
can select the model to edit. After selecting the model and clicking on OK, the Create
Threshold window opens so you can revise the thresholds for a particular electrical test
model.

Delete Test Model

Clicking on the Delete Test Model menu item opens the Select Test Model dialog box so you
can select the model to delete.

NOTE

Test models that are currently assigned and the default test model (default elec)
cannot be deleted.

6) When you attempt to delete a test model, a warning dialog opens to ensure that you
want to complete the operation.

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EXP4000 software overview

Tools menu

The Tools menu has a number of items that will assist in monitoring machines.

Figure 44. Tools menu.

Scope

Clicking on the scope menu displays a virtual oscilloscope. The virtual scope displays
currents, voltages, or acceleration as a function of time and frequency. It provides
information on:

• Phase-to-phase voltage

• Phase-to-phase current

Figure 45. Virtual Scope tool.

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EXP4000 software overview

Items found in the Settings menu provide you with options for defining the scope’s display
properties.

Figure 46. Scope tool Settings menu items.

Tools found in the bar below the Settings menu allow you to pause the scope display. When
the display is paused, you can click on the icons that appear to export data or save a screen
shot of the displayed waveforms

View Connections

This tools helps you view displays connections currently used. Check Connections appears in
red in the lower right corner (as in this example) if the connections are incorrect. When the
connections are correct, the Connections OK appears in green.

Figure 47. View Connections window.

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EXP4000 software overview

Transient Analysis

The Transient Analysis tools helps you capture startup transients via voltage and current vs.
time, and torque vs. time.

A button at the top left of the Transient Analysis window provides you with two options to
acquire transient data: Triggered Acquisition and Acquire Now.

Selecting Triggered Acquisition opens a dialog box of the same name that helps you select
the trigger source and level along with the acquisition time, CT, and pre-trigger time.

Figure 48. Triggered Acquisition dialog box.

Selecting Acquire Now opens the Manual Acquisition dialog box, which you can use to specify
the Acquisition time and CT selection. After specifying these parameters, clicking on OK
starts the acquisition process.

Figure 49. Manual acquisition dialog box.

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EXP4000 software overview

Figure 50. Transient Analysis—Voltage and current vs. time.

Figure 51. Transient Analysis—Torque vs. time.

When clicking on any point on either the voltage or the current displays, a marker depicts the
point in both panels, and the voltage and current data are displayed for that instant in time.
The Torque vs. Time tab displays two different views of the instantaneous torque. The
unfiltered torque displays in red showing the air gap torque’s highest level of dynamic
behavior calculated from the currents and voltages collected. The filtered torque displays as a
blue line showing the same information, but with a lower dynamic resolution. The blue line
can be considered the short time average of the red line. Additionally, the blue line describes
the fundamental behavior of the torque versus time while the unfiltered red line describes the
highest level of dynamic torque.

NOTE

Click the right mouse button over the cursor to open a dialog box that allows you to
delete data to right or left of the cursor.

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EXP4000 software overview

EP

The EP menu item gives you access to calibrate the EP and view the EP calibration. You can
also select the EP mode to use auto assign (when acquiring an EP serial number) or not, or to
use caching only.

Checking the Use EP Caching menu item reduces the time needed to begin acquiring EP
readings. Start of acquisition without EP caching is approximately 45 seconds. Enabling

caching reduces start of acquisition time to approximately six seconds.

Figure 52. EP menu items.

To view the EP calibration information, connect the EP to the Surveyor EXP AC then click on
View EP Cal.

Clicking on Calibrate EP opens the EP Calibration Wizard as shown below. Use the wizard to
facilitate calibration procedures and to configure CT connections. For more information on
EP calibration, click on Help then EP Calibration.

Figure 53. EP Calibration Wizard.

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EXP4000 software overview

Run Electrical

This tool is an alternate method for starting the electrical data collection. This option has the
same effect on the application as clicking the Run Electrical button found in the lower right
section of the Explorer window.

Looped Acquisition

The Looped Acquisition menu item contains two sub-items: Continuous and Timed.
Continuous mode will run as many consecutive tests as specified, with no interval between

tests.

Figure 54. Continuous Looped Acquisition.

Timed mode allows you to specify a number of continuous looped acquisitions to be repeated
in intervals that you specify.

Figure 55. Time-Looped Acquisition.

Dropdown lists help you select the starting and ending time conditions.

Vibration (option)

This tool is an alternate method for starting the vibration data collection. This option has the
same effect on the application as clicking the Run Vibration button found in the lower right
section of the Explorer window.

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EXP4000 software overview

Operating Curves

The Operating Curves tool provides you with options for graphically viewing the electrical data
for a particular test. The tool has three options: Torque vs. Speed, Efficiency vs. Load, and PF
vs. Load.

Figure 56. Torque vs. Speed operating curve display.

Figure 57. Efficiency vs. Load operating curve display.

Figure 58. PF vs. Load operating curve display.

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EXP4000 software overview

Raw to CSV

This tool provides you with the means to convert .raw test files to comma separate value
(CSV) files.

Speed Override

The Speed Override tool is used to manually enter the operating speed prior to performing
electrical measurements.

Figure 59. Speed Override selection dialog box.

Test Notes

The Test Notes menu item opens a dialog box that helps you create memos and identifies
who tested the motor ID.

Figure 60. Test Notes dialog box.

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EXP4000 software overview

Options

The Options tool provides you with the means to customize the data displayed and how the
electrical data is collected. Clicking on the Options tool opens the Options window, which
includes two tabs: Display and Acquisition.

Display tab

Use the Display Units field to define whether values will be displayed in Imperial (U.S.) or
Metric mode. The differences lie in that Imperial (U.S.) prefers Hp and lb-in for output power
of the motor and torque, respectively; the metric system chooses to display kW and Nm for
the same physical quantities.

The Voltage field allows you to select line to line or line to ground values when displaying
voltages.

The Database Directory field and Browse button help you select the location of the test
database.

Figure 61. Options window—Display tab.

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EXP4000 software overview

Acquisition tab

The Acquisition tab is used to select how the electrical data is collected.

Figure 62. Options window—Acquisition tab.

The Electrical Acquisition Options are used to change the acquisition time and define the
harmonics to save. You will also use this section to define the minimum and maximum
frequencies of interest.

The Spectrum Acquisition Options are used to define the acquisition time length, the
maximum frequency of the spectrum displayed, and the lines of resolution (LOR) to display.
The LOR controls the number of frequency bins (lines) that are displayed in the initial
spectrum presentation.

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EXP4000 software overview

Help menu

The Help menu provides access to several information resources to help you learn how to use
the product more effectively and to assist you in your testing efforts.

An electronic copy of the user manual can be access along with additional supporting help
targeted at the window currently opened when the Help item is selected.

Click on the About menu item to access current version information and a tool to check for
software updates.

The Release Notes menu item opens a document showing details about recent software
improvements.

Clicking on the EP Calibration item opens a document describing the EP calibration process
in detail.

The Motor Master+ item provides a link to the Motor Master+ website, which is an outside
resource for learning more about motor testing, repair, and replacement technology and
options.

Figure 63. Help menu.

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7 VFD4000 analysis software option

Variable-frequency drives (VFDs) are commonly used and highly useful. However, they can
be difficult to analyze due to their inherent variable nature.

Operation details

The VFD Details window can only be activated if the measurements were taken in VFD mode.
This window displays the dynamic behavior of voltage level, torque, frequency and speed as a
function of time.

1) To activate VFD mode, click on the Machine menu, Machine Properties item.

2) In the Machine Properties window Name Plate tab, check the VFD box.

VFD mode

The EXP4000 has two modes of operation: VFD, and non-VFD (60Hz or 50Hz) line operated.
For these two modes the connection requirements are slightly different. In VFD mode, the

Autophasing feature is off. Correct phasing of CTs with respect to voltage leads needs to be
ensured by the operator.

Each CT must be connected to the correct phase and with the correct polarity; otherwise, the
results displayed will not be correct. The following table displays issues and their
corresponding solutions.

Table 1. Testing Issues, possible connection causes, and actions.

Issue Possible Causes Action

V- and I- sequence do not coincide. Voltage is connected in abc and current

in acb sequence, or vice versa.

Speed negative, Torque negative, kW
positive, pf positive.

Three power factors (shown in Power
Quality domain, power result) are
negative or load is very wrong (FAR too
high or FAR too low).

Speed negative, torque positive (or vice
versa).

Voltage and currents are connected acb
with respect to electrical hardware.
Displays that the VFD is turning in
negative direction, motoring.

CTs are facing the wrong direction or
connected to the wrong phase.

a) Connected to a generator and not to
a motor.
b) CTs polarity is wrongly connected.

Swap two CT connections (for example,
swap red and yellow CT positions).

To obtain positive rotation data,
exchange Voltage clip from red to
yellow, and exchange CT from red to
yellow. Keep orientation of CT the
same.

a) Turn the three CTs around (reverse
direction of arrow).
b) Exchange cyclical locations of CTs
(red to yellow, yellow to blue, blue to
red). If results still not correct, perform
this step one more time; otherwise
check a).

a) Everything is fine
b) Turn the CTs around (reverse
direction of arrow).

NOTE

If in VFD mode, the voltage level is only displayed as a function of time. This mode
of operation is not a pass/caution/warning mode any longer. All voltage level tests
performed in VFD mode will yield a blue color.

VFD4000 analysis software option

Waveforms

In VFD mode, voltage and current for a phase is shown.

1) To open this window, click on the Connection domain button.

2) Click on the Waveforms button in the Connection domain panel.
In VFD mode, the voltage and current measurements can be displayed for only one phase at

a time, as you can see in the example below.

Figure 64. VFD waveform display.

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VFD4000 analysis software option

VFD Details domain

In VFD mode,this window displays the dynamic behavior of voltage level, torque, frequency,
and speed as a function of time.

As with any graphical display within the EXP4000 software, zoom and printing features are
available.

Figure 65. VFD Details window.

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68 Dynamic Motor Analyzer—EXP4000 User Manual

8 Continuous Monitoring Software option

Using a streaming process, the CM4000 Continuous Monitoring Software evaluates
important operating values of a machine application including triggered acquisition and
recording. It acquires 11 samples per second on 41 parameters.

The graphical user interface can be rearranged during operation to suit your particular
analysis needs. If recording, it stores all available channels, not only the ones displayed.

Figure 66. Continuous Monitoring – Main Panel

A large number of independently operating triggers can be set and the stored data can be
viewed.

NOTICE

Because the data generated over several days by the Continuous
Monitoring software is larger than what a Microsoft Access database can
accommodate, it is stored as a separate file within the same folder as
the motor database file. The external data files generated for each CM
recording event contain the motor database name suffixed with a recording
event number. The data files must be kept together with the motor
database for any data backup/move operations.

Continuous Monitoring Software option

File menu

The File menu is directly linked to the EXP4000 software. You can create a new database,
open an existing database, close an existing database, or exit the program.

Figure 67. File menu.

Machine menu

The Machine menu is interlinked with the EXP4000 software.

Figure 68. Machine menu.

Using the items in this menu, you can open the machine tree, create a machine, edit a
machine, and acquire or reset the EP serial number. Gathered information is recorded to the
database.

Tools menu

The Tools menu allows you to access the virtual scope or view the connections. Like other
menus, the Tools menu is directly linked to the EXP4000 software.

Figure 69. Tools menu.

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Continuous Monitoring Software option

View menu

Several preset views are available to evaluate data. Change views by clicking on the related
item in the View menu.

You can use the views as they are configured, or you can customize them by hovering the
mouse cursor over the view you want to customize, then click the right mouse button to open
dialog boxes used to modify the related view.

Figure 70. View menu.

View menu item Description

Volts/currents Root mean square of the current through phases A, B, and C. This number should be between

30% and 110% of the name plate current.

Voltages Displays the root mean square of the voltage for phase A, B, and C in volts.

Currents The displays the root mean square of the current through the phase A, B, and C CTs in amperes

along with the average of the root mean square values of the 3 phase currents in amperes.

Power factor The displays the power factor and the average power factor of phases A, B, and C . These values

are always equal to or smaller than one, and they increase with the load.

Power This displays the single-phase real power for phase A, B, and C and the total power in kilowatts.

Apparent power Displays single-phase complex power (9 kVA) values for phases A, B, and C in kilovolt amperes.

Reactive power Displays single-phase complex power for phases A, B, and C along with the sum of the thee

phases in kilovolt amperes.

Z angles Displays the angle between and the current phasors of phase A, B, and C and the average angle.

This number will typically vary between 90 degrees at no load to 20 degrees at full load for
induction motors.

Machine This view displays power out, torque, speed, and percent load. The power out is the mechanical

output power. The torque is the estimated torque in Nm or lb-in. The speed is the estimated
speed of ration of the shaft in RPM. The percent load is the output load with respect to the
motor’s rating in percentage.

New view You can create a custom view to display the items necessary to your operation.

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Continuous Monitoring Software option

Options menu

The Options menu has two items to choose from: Graph Plot Mode, and Event Triggers.

Graph Plot Mode

Within the graph plot mode, choose from sweep or continuous. When operating in sweep
mode, a red bar will sweep from left to right across the screen.

Figure 71. Options menu.

In continuous mode the tool will continue to gather data and the screen will change as it
reaches the far side and continues forward.

Event Triggers

Event triggers are useful for monitoring data for predefined machine events. When the
chosen condition exists, the data will be recorded for review. The software will continue to
record all channels until all triggers have been recorded. At that point, the software will stop
and all events can be reviewed. The software can monitor any or all of the 41 active triggers
listed. All channels are continuously monitored and each trigger creates a separate event,
even if the time is overlapping.

Figure 72. Event Triggers window.

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Continuous Monitoring Software option

1) To set up event triggers, click on Options, then Event Triggers.

2) Check the box for each trigger needed.

3) Set the parameters needed for each trigger:

4) Click on OK to save your settings.

Parameter Description

Start Condition Set this to either greater than or less than the value. Click on down arrow to

reveal other choices.

Start Value Type the number value appropriate for this trigger.

Stop Condition Set this to either greater than or less than the value. Click on down arrow to

reveal other choices. Remember this must be different from the start condition.

Stop Value Type the number value appropriate for this trigger. Remember this must be

different then the start value.

Pre-Trigger (sec) Number of seconds prior to event the software records data.

Post-Trigger (sec) Number of seconds post to the event the software records data.

NOTE

If the Pre- and Post-Triggers are set to zero, the data that is recorded is just the
event. If these are set to greater than zero, data will be recorded that gives
information on what led up to the event and what happen after if occurred.

General operation icons

The CM4000 software has a few built-in icons that provide shortcuts to specific operations.
They are shown in the graphic below.

Figure 73. CMS general operation icons.

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Continuous Monitoring Software option

Modifying the continuous monitoring tool

The continuous monitoring software tool is customizable. It features 41 different gauges and
graphs that can be added to your display or modified to enhance the value of information
being collected.

You can set up the tool with as many of the graphs and gauges as you prefer; and you can
change these elements to suit your needs. This is accomplished by hovering the mouse
cursor over specific areas of the window and clicking on the right mouse button.

Adding a new gauge or graph

1) With the cursor in a white space around the existing gauges, right-click the mouse
button and a menu will pop up for adding a new gauge or graph.

2) Click on either New Gauge or New Graph.

3) A list of available object will appear. A few of the options are shown in the example
below.

4) Click on the desired gauge or graph to be added.

5) The new object will appear on your display and can be positioned as needed within
the window.

Figure 74. New Gauge / New Graph menu with sample items.

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Continuous Monitoring Software option

Moving gauges and graphs

1) Hover the mouse cursor over the item you want to move and click on the right
mouse button. The menu shown below appears.

2) Click on Move. A hand graphic appears over the object to move.

3) Drag the object to the new location and click the left mouse button to set the object
in place.

Figure 75. Move menu item—right mouse button click.

Setting gauge and graph scales

1) Hover the mouse cursor over the object you for which you want to define scales then
right-click the mouse.

2) Click on AutoScale or Manual as desired. The dialog box shown in the example
below appears when AutoScale is selected. The Manual scale selection will have a
similar dialog.

3) Set the values for scaling as needed then click OK.

Figure 76. Scale menu item—AutoScale.

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Continuous Monitoring Software option

Defining channel for the graph or scale

1) Hover your mouse cursor over the object for which you want to define the channel
then click on the right mouse button. A menu like the one shown below appears.

2) You can click on any of the channels and the graph or gauge will automatically
change to that item. Descriptions for the available channels are provided in the table
on the next page.

Figure 77. Channel menu.

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Continuous Monitoring Software option

Channel descriptions

The table below contains channel descriptions that include input data to the CMS software
along with data calculated by the CMS software.

Table 2. CMS channel descriptions.

Channel Description

IA RMS [A] Root mean square of the current through the phase A-CT in

amperes. This number is typically between 30% and 110% of the
nameplate current.

IB RMS [A] Root mean square of the current through the phase B-CT in

amperes. This number is typically between 30% and 110% of the
nameplate current.

IC RMS [A] Root mean square of the current through the phase C-CT in

amperes. This number is typically between 30% and 110% of the
nameplate current.

VA RMS [V] Root mean square of the phase A voltage.

VB RMS [V] Root mean square of the phase B voltage.

VC RMS [V] Root mean square of the phase C voltage.

I Avg RMS [A]

V Avg RMS [V] Average of the root mean square values of the three phases’

I Imbal [%] Current imbalance percentage. For machines under load, this value

V Imbal [%] Voltage imbalance percentage.

IA Angle [deg] Angle between the current phasor of phase A with respect to the

IB Angle [deg] Angle between the current phasor of phase B with respect to the

IC Angle [deg] Angle between the current phasor of phase C with respect to the

Average of the root mean square values of the three phases’ currents
in amperes.

voltages.

is typically smaller than one eighth of the voltage unbalance
percentage.

voltage phasor of phase A (which is locked at 0 degrees). This
number is equal to Za angle.

voltage phasor of phase A—in degrees). This number is Zb angle
degrees away from Vb angle.

voltage phasor of phase A—in degrees). This number is Zc angle
degrees away from Vc angle.

VB Angle [deg] Angle between the voltage phasor of phase B with respect to the

voltage phasor of phase A—in degrees. This number typically should
be within three degrees of either 120 or 240 degrees.

VC Angle [deg] Angle between the voltage phasor of phase C with respect to the

voltage phasor of phase A—in degrees. This number typically should
be within three degrees of either 120 or 240 degrees.

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Continuous Monitoring Software option

Channel Description

ZA Angle [deg] Angle between the voltage and current phasors of phase A, in

degrees. This number will typically vary between 90 degrees at no
load to 20 degrees at full load for induction motors.

ZB Angle [deg] Angle between the voltage and current phasors on phase B, in

degrees. This number will typically vary between 90 degrees at no
load to 20 degrees at full load for induction motors.

ZC Angle [deg] Angle between the voltage and current phasors on phase C, in

degrees. This number will typically vary between 90 degrees at no
load to 20 degrees at full load for induction motors.

Z Angle Avg [deg] Average angle between the voltage and current phasors on their

respective phases, in degrees. This number will typically vary
between 90 degrees at no load to 20 degrees at full load for
induction motors.

Power A [Kw] Single phase real power for phase A, in kilowatts.

Power B [Kw] Single phase real power for phase B, in kilowatts.

Power C [Kw] Single phase real power for phase C, in kilowatts.

Total Power [Kw] Total real power, in kilowatts. It is equal to Pa + Pb = Pc.

Reactive Power C [kVAr] Single phase reactive power for phase C, in kilovolt amperes.

Reactive Power Avg [kVAr] Sum of the three phases’ reactive power, in kVAr.

V over F It displays the instantaneous ratio of voltage level divided by

fundamental frequency of the voltages. For all line-driven
machinery, this must be a constant. For most VFD applications, it
also needs to be near a constant value.

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9 Vibration software option

The vibration software allows you to collect and analyze vibration probe data. The software
can be accessed in two ways: from the Run Vibration button in the Explorer window (lower
right), or from the Tools menu.

When the Vibration window opens, the last vibration scan is displayed on the screen.

Figure 78. Vibration window.

Controls found at the top of the window help you select test results for viewing, set
parameters for the display, and perform other related functions with the test data.

Figure 79. Vibration window controls.

Clicking on the down arrow to the right of the Run Vibration icon opens a menu so you can
choose how you want the test to run. Options include: Run 1 Now, Looped Acquisition, and
Time Looped Acquisition.

Clicking on the Run Vibration icon initiates the data acquisition process. The instrument
acquires data for 10 seconds then automatically save the results and displays the scan in the
window’s display area.

The Test Selection dropdown list and the Next/Previous Record arrows help you select
previously recorded data files for viewing.

Clicking on the Export Data icon opens a window so you can save the data to the location of
your choice as either a comma separated values (CSV) or tab delimited (TXT) file.

Vibration software option

Clicking on the Plot Settings icon opens the Graph Settings dialog box as shown below.

Figure 80. Graph Settings dialog box.

This dialog box helps you select the parameters and options that will be used to display the
related vibration scan.

Clicking on the Vibration Gain Multiplier icon opens a dialog box in which you can specify
the gain to be used for the related vibration scan.

Running a looped acquisition scan

1) To run a looped acquisition, click on the down arrow next to the Run Vibration icon
then click on Looped Acquisition. A dialog box like the one shown below appears.

2) Type in the number of tests to be conducted (the default is 10).

3) Click Start and the instrument will loop through the given number of tests at
10-second intervals, automatically saving the results as each test completes.

Figure 81. Looped Acquisition dialog box.

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Vibration software option

Running a time-looped acquisition

1) To run a time-loop acquisition, click on the down arrow next to the Run Vibration

icon then click Time Looped Acquisition. A dialog box like the one shown below
appears.

2) Type in the number of tests to be conducted along with the time intervals.

3) Click Start and the instrument will run the required number of tests at the time

interval specified, automatically saving the results as each test completes.

Figure 82. Time Looped Acquisition dialog box.

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Vibration software option

Viewing results

Several options are available for viewing vibration test data, starting with selecting one of the
window tabs: Time Waveform, Spectrum, and Trending. In addition, clicking on the Plot
Settings icon reveals additional options depending on the tab selected. The display area in
the Vibration window changes to match each viewing option selected.

Viewing Time Waveform results

For the Time Waveform tab, clicking on the Plot Settings icon reveals three additional
options: Acceleration, Velocity, and Displacement.

Figure 83. Time Waveform display options.

A Time Waveform acceleration example display is shown below.

Figure 84. Time Waveform—Acceleration.

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Vibration software option

Viewing Spectrum results

Using the Spectrum tab as an example, clicking on the small arrow to the right of the Plot
Settings icon reveals additional options: in this case, Acceleration, Velocity, Displacement,
Markers, and Graph Settings. Not all options are available for every test conducted. Those

that are not available are grayed out; other that do not apply to the mode selected will not
appear in the list.

Figure 85. Spectrum display options.

Several examples of Spectrum displays follow.

Figure 86. Spectrum—Acceleration.

Notice that the Spectrum tab features a graph settings pane to the left, which provides
control over additional graph settings to those controlled from the Graph Settings dialog
box accessed from the Plot Settings icon.

Using the graph settings pane, you can quickly switch the Plot Mode, and the display
parameters for the X-axis and Y-axis.

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Vibration software option

Using the Markers section, you can select markers to display by checking the box next to the
marker(s). In the Spectrum Velocity example below, the Speed marker box is checked and
the marker appears in the display. In addition, the example shows how you can move the
marker’s location to enhance the view.

1) Hover the mouse cursor over the marker then click and hold down the left mouse
button. A four-cornered arrow appears indicating that the object can be moved.

2) Continue to hold down the mouse button and drag the object to its new location
then release the mouse button.

This feature can be used for any of the objects in the display.

Figure 87. Spectrum—Velocity.

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Vibration software option

In the Spectrum Displacement example shown below, we see that several markers are used
and have been moved to new locations to improve viewing. In addition, this example
demonstrates how the green and black cursors can be moved within the display.

1) To move either of these cursors, hover the mouse cursor over one until you see a
four-way arrow.

2) Click and hold the left mouse button and drag the cursor along the waveform to the
desired location then release the mouse button.

NOTE

The green cursor is a differences cursor, which displays differences in X and Y values
between its location and that of the black point of interest cursor.

Figure 88. Spectrum—Displacement.

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Vibration software option

If you look closely at the preceding example, you will notice that a new set of markers has
been added to the list—the “SKF” markers. These markers are added by clicking on the
green plus ( + ) icon just below the Markers list. The Select Marker Type dialog box like the
one shown below opens to help you make your selection.

Use the dropdown lists to select the marker type, company, and model.

Figure 89. Setting marker types and harmonic settings.

To set the Harmonics settings for a marker, click on the check box next to the marker in the
Markers list then used the From and To selection boxes in the Harmonics setting pane to
define your parameters.

86 Dynamic Motor Analyzer—EXP4000 User Manual