Explorer - Manual DC

DC3000 Online Motor Monitoring
Users Manual
DC3000 DC Online Motor Monitoring Software
Baker Instrument Company, an SKF Group Company 4812 McMurry Avenue Fort Collins, CO 80525 (970) 282-1200 (970) 282-1010 FAX (800) 752-8272 USA Only Technical @bakerinst.com
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Users Manual DC3000 DC Online Motor Monitoring Software

Baker Instrument Company, an SKF Group Company 4812 McMurry Ave. Suite 100 Fort Collins, CO 80525 (970) 282-1200 (970) 282-1010 (FAX) 800-752-8272 (USA Only)
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 nor 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. Warning: Baker Instrument Company, an SKF Group Company assumes no liability for damages consequent to the use of this product. No part of this document may be reproduced in part or in full by any means such as photocopying, photographs, electronic recording, videotaping, facsimile, etc., without written permission from Baker Instrument Company, an SKF Group Company, Fort Collins, Colorado. While the DC3000 software is a PC based software, it has a specific configuration and directory structure that is necessary for the unit to function correctly. If these directories or files are tampered, the unit may not function correctly or reliably.
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DC3000 Online Motor Monitoring Baker Instrument Company, an SKF Group Company Software License Agreement DC3000 Test Equipment and Desktop versions Carefully read the following terms and conditions before opening the software envelope; either opening the envelope or using the software constitutes your acceptance of these terms and conditions. If you, the licensee, do not agree with them promptly return the package unopened for a full refund. The DC3000 Program and Documentation are the property of Baker Instrument Company, an SKF Group Company as copyright owner. Baker Instrument Company, an SKF Group Company licenses its software for use; it does not transfer ownership. By the acts of opening the sealed diskette package and making full payment of the required amounts, the User has been granted a personal, non-exclusive license to utilize the Program and Documentation. The term Program refers to both the specific DC3000 software already installed on the test equipment simultaneously purchased (the Test Equipment Version) and, if applicable, to one specific copy of the desktop version of the EXP3000/EXP3000R software provided in CD ROM form for use on the users separate computer (the Desktop Version). The term Documentation refers to the associated instructions and reference materials. Both Program and Documentation also include any enhancements, modifications, revisions, or additions, which Baker Instrument Company, an SKF Group Company directly or indirectly releases to the User. License: The license granted permits the User to do only the following: 1. Use the Test Equipment Version on only the Baker test equipment provided; 2. If applicable, use the Desktop Version on only a single, approved computer. (The list of approved computers is 4
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DC3000 Online Motor Monitoring available upon request) and only in conjunction with the Baker test equipment; 3. Use the Program and Documentation for business and commercial purposes only; 4. Utilize the Documentation only in conjunction with the use of the Program. These are the only rights granted. The User has no right to, among other things: to use the Program on more than one computer or on a computer which has not been approved for use; to transfer sublicense or rent the program, or to authorize another to do so, or to create derivative works based upon any part of the Program. The rights granted by the licensee shall terminate (without refund) automatically upon the Users failure to abide by the terms or conditions of this License or by any combination by the User to any infringement of any proprietary rights owned or licensed by Baker Instrument Company, an SKF Group Company. In event of any termination, the User agrees to return all Programs, Program diskettes, Documentation and all copies thereof. In addition Baker Instrument Company, an SKF Group Company from time to time updates its Programs and Documentation for registered users. If the User is not registered, it may not receive an update. In the event an update is received, the User agrees to destroy or return the original Program or Documentation and acknowledges that the update will be governed by the terms of this license also.
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DC3000 MACHINE ONLINE ANALYSIS SOFTWARE ........................................... 9
DC Summary of Tests & Features ............................................................9 Types of Problems Identified with DC3000 ..........................................9
CHAPTER
1 ................................................................................................ 11
CONNECTION CASES .................................................................................. 11 DC CONNECTIONS FOR THE EXP3000 PORTABLE SENSORS: .......................... 13 CHAPTER 2 ................................................................................................ 17
SOFTWARE NAVIGATION ......................................................................... 17 DC3000 SOFTWARE NAVIGATION .................................................................. 19

Renaming a New Folder .............................................................................21 Adding an Dc Machine ................................................................................22 Adding an Armature ....................................................................................25 Database or Folder View ............................................................................26 Create Archive ...............................................................................................28 Restore Archive .............................................................................................28 Compress & Send To: .................................................................................29 Options .............................................................................................................34 General Options: ..........................................................................................35 Database Options .........................................................................................36 Archive Options .............................................................................................36
ONLINE TESTING MENU .................................................................................. 30
CHAPTER
3 ................................................................................................ 39
SOFTWARE TESTING SCREEN ................................................................. 39 SOFTWARE TESTING SCREEN .......................................................................... 41

CT Selection....................................................................................................41 Nameplate Information ..............................................................................41 Center Screen ................................................................................................42 Bottom Main Screen ....................................................................................43 Run Electrical .................................................................................................44 View Connections .........................................................................................44 Exit .....................................................................................................................44 Test Domains .................................................................................................44
CHAPTER
4 ................................................................................................ 47
TEST DOMAINS ............................................................................................. 47
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Armature Voltage Level (Va) ...................................................................49 Field Voltage Level (Vf) ..............................................................................51 Armature Voltage Form Factor ................................................................56 Armature Current Ripple............................................................................58 Armature Current Level .............................................................................60 High Field Resistance ..................................................................................61 Low Field Resistance ...................................................................................63 Field Current Level .......................................................................................64 Torque Ripple .................................................................................................67 Load Level .......................................................................................................68 Field Spectrum ..............................................................................................71 Armature Spectrum .....................................................................................72 Torque Spectrum ..........................................................................................73
CHAPTER
5 ................................................................................................ 77
REPORTS......................................................................................................... 77
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DC3000 Machine Online Analysis Software

DC Summary of Tests & Features Collect and Graph Field Voltage Collect and Graph Field Current Collect and Graph Armature Voltage Collect and Graph Armature Current Collect and Graph Transient Data including Start Up Transient Calculate Instantaneous Torque and Graph Torque Ripple and Torque Spectrum Calculate Harmonics on all Voltage and Current data Calculate Current Spectrum Calculate Voltage Spectrum Cursors available to analyze Torque and Current Spectrum data Data can be exported for additional analysis with programs such as Matlab or Excel Types of Problems Identified with DC3000 Firing Sequence and Firing Angle Issues Voltage Unbalance Issues Voltage Level Issues Analyze Voltage Form Factor Measure Incoming Power Condition Failed SCRs (or in the rare occasion they are used, failed IGBTs) Diagnose Brush Fire Diagnose Brush Chatter Diagnose Drive issues Diagnose Commutator Problems Analyze/Troubleshoot Response of Motor Circuit Analyze/Troubleshoot Load issues Analyze/Troubleshoot I2R issues Assists in setting Neutral Plane
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CHAPTER CONNECTION CASES

Inside this chapter
Basic Diagram Separated Excited DC Motor
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DC Connections for the EXP3000 Portable Sensors:

DC Sensor Voltage Ratings
Warning: The maximum rating of the EXP DC voltage circuit is 500V. 500V is the maximum allowable voltage between any two of the 4 voltages and the ground clip. Under not circumstance connect the voltage sensing circuit to higher voltage levels.
Warning: The maximum voltage rating of the EXP DC current meters are up to 600V. Under no circumstance connect the current sensors to circuits of any higher voltage. Terminology: Va Armature Voltage Ia Armature Current Vf Field Voltage If Field Current
Fig 1-1: Basic Diagram-Separated Excited DC Motor
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Connection Cases
Current Sensor Connections: Warning: The maximum voltage rating of the EXP DC current meters are up to 600V. Under no circumstance connect the current sensors to circuits of any higher voltage. I) Ia 600A, If 100A Portable Sensors Standard DC
Standard DC3000 Current Sensors has two ranges: 60A/600A 10A/100A Ia If
II) 600A Ia 15,000A, or If> 100A Optional DC Portable Sensors Optional DC current sensors are available, extending the current range above 600A for the armature, and/or above 100A for the field.
Fig 1-2 Connection Diagram
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Voltage Sensor Connections: V500V The EXP voltage connection is make directly across the Armature voltage, or Field voltage. The figure below shows the field voltage connections.
Fig 1-3: Portable Field Voltage Connection Less Than or Equal to 500V
V> 500 V If the DC motors voltage exceeds 500V, then a resistive bridge can be used to supply a lower, proportional voltage to the EXP3000. The figure below shows this done for the Field Voltage circuit.
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Fig 1-4: Portable Field Voltage Connection Greater than 500V
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CHAPTER SOFTWARE NAVIGATION

Inside this chapter
Creating a New Database Opening a Database Close Database Creating a New Folder Create a New Test Item Database or Folder View Archive Menu Create DC Test Model Edit Test Model Delete Test Model Looped Acquisition Options Menu
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DC3000 Software Navigation
Fig 2-1: File Dropdown
Creating a New Database

1. Click on File and then New Database. The following screen will appear. Type a name for the new database that is appropriate to the operation and click OK 2. This database will now appear in the Tree View on the Left Hand side of the screen. There are three types of database structures to choose from. a. Access Database (*.mdb) b. Sql Express Database (*.mdf) c. Sql CE Databse (*.bic) 3. Choose the database structure appropriate to the application.
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Fig 2-2: Create New Database
Opening a Database
1. To open a database, click on File and then on Open Database. 2. The following screen will appear. Choose the
Fig 2-3: Open Database
appropriate database and click on Open. 3. This database will be active on the software.
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Close Database
Too close a database, click on File and then on Close Database. This will close the database.
Creating a New Folder

Too create a New Folder, click on File and then on New Folder. The new folder will locate itself in the Tree View.
Fig 2-4: New Folder
Renaming a New Folder 4. To rename a New Folder, rightclick on the new folder and then on Rename in the drop-down box and it will place a box around New Folder. Type in the appropriate name and press enter or click outside of the folder.
Fig 2-5: Rename Folder
Create a New Test Item

1. To create a New Test Item, click on File and then on New Test Item. A Wizard will appear to help with creation of the new machine.
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Fig 2-6: Create New Machine
2. Type in the appropriate Machine Name and click on whether it is a Dc Machine or an Armature. Click Next. Adding an Dc Machine 3. Dc Machine: Notice that there are a number of fields that have drop down boxes. Many of these fields are required. a. Number of poles: 2, 4, 6 b. Has Interpoles: Yes/No c. Winding: Chooses between Shunt, Compensated Shunt, or Permanently Excited d. Insulation Class: A, F, B, or H. e. Number of Commutator Bars: an up/down arrow displayed in multiples of 2.
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Fig 2-7: Nameplate Information
4. Required fields are listed in Bold. Yellow fields are mostly required, but are also listed for non-required but also important to have. After all pertinent information is entered choose either to Validate, Skip Validation (if using offline equipment), Cancel or Finish. Note: If using the online equipment validation is necessary to verify the required information for accuracy. If information is not accurate, erroneous testing results may occur.
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Fig 2-8: Validation
5. Verify the information on the validation screen and if pertinent choose an application that the motor is using. If an application is not in the list it can be added by highlighting the first application bar and typing the description of the application.
Fig 2-9 Validation - Manufacturer
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6. After all information has been entered, click on Finish to add to machine to the list in the tree. Adding an Armature This feature operates only with the combined software. Since an armature is a component of a machine and not an entire machine, no data can be obtained via the online testing.
Right Click Menu Items
Fig 2-10: Right Click Menu
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DC3000 Online Motor Monitoring Within the Navigation Pane of the EXP3000 DC software there is a right click menu that will help the user do a number of activities. This is a convenient menu to accomplish these tasks easily and quickly. Database or Folder View If located on a Database or Folder View these functions include creating a New Folder which contains: New Database, New Folder, AC Machine, DC Machine, Armature and Bucket. The Armature and Bucket buttons are specifically used in the offline testing equipment alone and does not affect the online testing procedures. Also included are the Database Functions of Open or Close databases, Compress and Send To, and Database menus. The Compress and Send to menu offers the ability to transport data from one point to another. The data can be sent to a flash drive, to the Desktop, to My Documents, to a Mail Recipient or the needed folder can be browsed to. This transportation of data is extremely important for moving test data from one place to another. For instance if there has been testing done on a group of motors within a database and that data needs to be synchronized with the main database or desktop version of the software this database can be sent to a file in these locations. This data will go to the designated file for Archives and split to match size requirements stipulated in the Options. See Tools: Archive for more information on this feature. Finally the Database Compact and Repair mechanism helps keep the data in good operational order and helps the user Repair the database if file corruption has occurred. This mechanism is for Access
Fig 2-11: Right Click MenuProperties for Machine Level
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DC3000 Online Motor Monitoring database structure only and is equivalent to a defrag on a hard drive. There are also Delete folders or machines, Rename the items in the Navigation Pane, change the style of the view screen to Grouped from Standard which is used for viewing on some computer screens. The Open File Location is operated from the Database level only, and opens a Window showing where the file is located on the drive. Finally, Properties for the Database and Folder level offer a brief bit of information on what the database or folder is named and when it was last modified. Properties at the Machine level are much more intensive and show all information that was entered via Nameplate, Machine Application, Manufacturer, Online Testing and Bearings. Some items within these tabs can be edited.
Fig 2-12: Right Click Menu-Properties
Archive Menu
Backing up data is highly important in order to keep data safe from loss. Data loss is extremely expensive and care needs to be taken in order to safeguard testing data.
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DC3000 Online Motor Monitoring Create Archive 1. To create an archive, click on Archive. 2. Click on Create. The Archive will automatically be made. It writes the archive to the file that is designated within the Options menu. This archive is meant to be used as a backup to the system. See Tools: Options for more information on this feature.
Fig 2-13: Create Archive
Restore Archive 1. To Restore an Archive, click on Archive and the Restore.
Fig 2-14: Restore Archive
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DC3000 Online Motor Monitoring 2. Choose the databases that are needed to be restored and press Open. 3. The same style progress bar will appear and complete the process. Compress & Send To: There are three choices within this menu. Choose to send the archive to the Desktop, to the Documents or Browse to a folder that the file should be included to. This allows the backup file to be housed on the computer hard drive or many other drives available. Flash drives will also be an available option if a drive is plugged into one or more of the USB ports.
Fig 2-15: Compress and Send To
1. To add the file to the desktop or My Documents, simply press the Desktop button and the file will automatically add to the Desktop or the My Documents Folder. 2. When Browsing to a file
Fig 2-16 Browse
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DC3000 Online Motor Monitoring folder the following Windows screen is displayed. This allows the user to place the folder anywhere on the hard drive or onto a network drive.
Online Testing Menu

In order to begin testing, a few tasks must be completed. The user needs to have an understanding of what is being tested. Within the Online Testing menu is the ability to Create, Edit or Delete Dc Test Models. These models house thresholds for both Caution Levels and Warning Levels for a number of items.
Create Dc Test Model

1. To create a Dc Test Model, click on Online Testing and the on Create Dc Test Model
Fig 2-17: Online Testing Menu
2. Under Test Model Name type in an appropriate name for the Test Model. These names should make sense to the application that is being done. 3. Change any of the threshold levels that are appropriate by highlighting the threshold level and typing in the appropriate number. Remember the Warning Levels must be higher than the Caution Levels.
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Fig 2-18: Create New Test Model
Edit Test Model

1. Click on Online Testing and then click Edit Test Model. 2. The following screen will appear. Choose the Test Model to be edited from the list under Select Test Model to Edit. Edit all items that are necessary.
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Fig 2-19: Edit Test Model
3. Click on Apply and then on Close. This will save the changes to this test mode.
Delete Test Model

To delete a test model: 1. Click on Online Testing and then on Delete Test Model. 2. Choose the appropriate test model to be deleted from the drop down box.
Fig 2-20: Delete Test Model
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DC3000 Online Motor Monitoring 3. Click on Delete. A confirmation box will appear. Please double check that this is the Test Model to be deleted and then click on the appropriate response.
Looped Acquisition
Fig 2-21: Looped Acquisition
The user can set the equipment to continually run in a looped mode for a specific number of tests. 1. To access the looped acquisition mode click on Online Testing and the Looped Acquisition 2. Highlight and type in the appropriate number of tests or use the up and down arrows to reach that number. 3. Click start after set up is completed. 4. The instrument will count down and count up the number of tests remaining and completed.
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Options Offline Testing Menu

The offline testing menu will be dedicated to offline testing. For this manual, that section of the software will not be discussed. This section will not be active on the online equipment if offline equipment is not owned by the end user.
Tools
Fig 2-22: Tools Menu
There are two types of tools within the Tools Menu. The Motor Master+ tool gives the end user a research tool for motor efficiencies and workability. It helps the user find motors of like size, capabilities, and efficiencies. It will also allow the user to research motor details to see if it is working within prescribed tolerances. Options There are three different types of options with this menu. These options allow the user to customize several database features.
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Fig 2-23: General Options
General Options: Within the General Options set the calculation path to locate the calculator. This will allow access to an online calculator. Currency can be set from here. The default is the US Dollar. 1. Type in the current that is appropriate for your region 2. Select the currency symbol from the drop down box that represents the money chosen.
3. Set the KWH price to help calculate efficiencies and cost savings. 4. Select from the drop down box the equivalent unit of currency either US or Metric. 5. Screen colors can be changed by clicking on any of the color schemes listed.
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6. To save changes click on apply and then OK. Database Options
Fig 2-24: Database Options
The database options menu allows the user to set the location for the database files and to set what type of database is to be used as the default. The user can select from Access Database (*mdb), Sql Express Database (*.mdf), or Sql CE Database (*.bic). Archive Options This option allows the user to set the location of where archives are housed. This was mentioned in previous sections of the manual about creating or updating archives. This is an important feature to remember if ever looking for or needing to locate an archive that has been made.
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DC3000 Online Motor Monitoring Also, the Explorer creates a great deal of data points. These data points can create large databases of many mega-bytes. Within this option menu, the Max Archive Size can be set so that it can be easily sent to different devices without issue. If the database is larger than the archive max size, the software will break the file size to appropriate pieces and archive all of the data.
Fig 2-25: Archive Options
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CHAPTER SOFTWARE TESTING SCREEN

Inside this chapter
CT Selection Nameplate Information Center Screen Bottom Main Screen Test Domains
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Software Testing Screen

The following description of the following components on the opening screen of the DC3000 software will aid in understanding how the software will gather data.
Fig 3-1: Main Screen
CT Selection On the top of the screen is a row of CT selections, one for the Field CT and one for the Armature CT. There are two selections in each. The Field CT is either 10A or 100A whereas the Armature CT is either 60A or 600A.
Fig 3-2: Top of Screen CT Selection
Nameplate Information The information listed in the grey top portion of the screen is from the nameplate information that was entered with the
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DC3000 Online Motor Monitoring machine was created. This gives the user a reference to what was originally listed for the machine.
Fig 3-3: Top of Screen Nameplate Info
For comparison reasons this information will be beneficial when analyzing results from tests. Center Screen
Fig 3-4: Center Main Screen
Va [%] = Percentage of Synchronous Speed If

VA[%] = Armature Voltage Percentage VF[%] = Field Voltage Percentage IA[%] = Armature Current Percentage IF[%] = Field Current Percentage Torque [ft-lb] = Torque in Foot Pounds (torque [N-m] = Torque in Newton meters) Load [HP] = Load in Horse Power (Load [kW] = Load in 42
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DC3000 Online Motor Monitoring kilowatts) Load [%] = Percentage Load Va/If [%] = Percentage of Synchronous Speed Equivalent Parameters: Waveforms can be zoomed into display cycles: Practical data resulting from the Waveforms: Firing sequence Fining angles determined by amplitude of waveform o Broken SCR-Extreme Firing Angle Input Voltage Unbalance Phases may be off; lack of symmetry in Waveforms 3 phase (3+, 3-) SCR switching Symmetrical Waveforms, unless too much ripple is present Typical DC drives will not have a flat waveform, due to Six-pulse rectifiers or lack of ripple capacitors. Rule: The field circuit does not interact with load. All load related signatures will make it into the armature but not the field. Bottom Main Screen
Fig 3-5: Bottom of Main Screen
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DC3000 Online Motor Monitoring Run Electrical Click on Run Electrical to run programmed tests. View Connections
Fig 3-6: View Connections
The view connections window gives a real-time look at the input signals. Va, Cf, Ia and If are displayed in terms of Average, RMS, Min/Max, Peak-to-Peak and Percent of Nameplate. The graph shows waveform shape. Load and Torque are plotted versus time. Exit By clicking this button, the software will exit to the desktop. Test Domains The following screen has a set of test buttons where all of the test domains are located. A great deal of information concerning the machine under test is housed in these large buttons. Click on each individual button to see a subset of buttons and then several test results screens.
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Drive Armature Voltage Level, Field Voltage Level, Armature Voltage Form Factor, Armature Current Ripple Machine Armature Current Level, High Field Resistance, Low Field Resistance, Field Current Level Load Torque Ripple, Load Level Waveforms Results Only Spectrum Field Spectrum, Armature Spectrum, Torque Spectrum Harmonics Results Only
Fig 3-7: Test Domains
Results: Green Machine running within tolerances. No action needed. Yellow: Machine is showing a caution symbol. Action should be taken to avoid future problems. Red: Machine is showing a warning symbol. Action needs to be taken to correct problem. Blue: No applicable thresholds.
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CHAPTER TEST DOMAINS

Inside this chapter
Drive Machine Load Waveforms Spectrum Hamonics
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Drive
The Drive domain takes a look at the upstream power. Poor power condition will expose the motor to unnecessary stress. 1. Click on the Drive button to view the tests involved with this domain. 2. Click on any of the tests to view the Results or Test Logs. Armature Voltage Level (Va)
Fig 4-1: Armature Voltage Level
Function of Va: Armature Voltage Level being the main variable to control speed is always created by the d rive; speed varies proportionally to Va. To change speed, change Va. To reverse direction of rotation, reverse Va
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Speed =
And
k (Va Ia Ra If
Synchronous Speed =
Boundary:
Va If
Nominal:-VA_Nameplate<Va<Va_Nameplate Warning Threshold: 120% Va_Nameplate Caution Threshold: 110% Va_Nameplate Standards: NEMA MG-1 Section 1-12.64 Result: |Va|>Va nameplate Possible Root Cause: Drive Settings and motor nameplate data do not coincide Drive or sensor problem. Malfunctioning control circuit or feedback Neutral Plane is off Possible Effects: Overspeeding of the motor Brush Fire Excessive brush sparking due to armature over voltage. Commutator/Brush Damage
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Field Voltage Level (Vf)
Fig 4-2: Field Voltage Level
Function Connecting Vf onto the field winding cause the flow of If, which creates the magnetic field necessary for torque generation. Boundaries Nominal: |Vf_field_weakening| < |Vf| < |Vf_base_speed| Warning Thresholds: 120% |Vf_base_speed| 80% |Vf_field_weakening| Caution Thresholds: 110% |Vf_base_speed| 90% |Vf_field_weakening| Standards: NEMA MG1 Section 1-12.64 Results: |Vf| > |Vf_base_speed|:
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DC3000 Online Motor Monitoring Case I: If <= If_base_speed Possible Root Cause: Field circuits resistance is higher than nameplate suggests. Field winding is running too hot Contact resistance in the field circuit The field circuits lead lengths cause additional voltage drop prior to reaching field winding terminals. Field circuit is not properly represented by the Motors nameplate Error entering the nameplate when creating the motor. Possible Effects: If contact resistance in field circuit
Contact resistances tend to increase over time. Following this trend, the worsening contact resistance will lead to overspeed trip, or overspeed damage to the motor. Many drives have motor models used to offer higher quality speed / torque controls. The fields resistance varying too much from the drives motor model may introduce stability problems to speed or torque control. On inexpensive motors with no speed control, the motor can overspeed, possibly damaging the motor. If field lead lengths cause additional voltage drop prior to reaching field winding terminals.
Many drives have motor models used to offer higher quality speed / torque controls. The fields resistance varying too much from the drives 52
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DC3000 Online Motor Monitoring motor model may introduce stability problems to speed or torque control. On inexpensive motors with no speed control, the motor can overspeed, possibly damaging the motor. If Motors nameplate doesnt properly represent the field circuit
Many drives have motor models used to offer higher quality speed / torque controls. The fields resistance varying too much from the drives motor model may introduce stability problems to speed or torque control. Case II: If > If_base Possible Root Cause: Drive setup problem Drive or sensor malfunction. Short in field.
Possible Effects: Many drives have motor models used to offer higher quality speed / torque controls. The fields resistance varying too much from the drives motor model may introduce stability problems to speed or torque control. In case |Vf| < |Vf_field_weakening|: Case I: If < If_field_weakening Possible Root Cause:
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DC3000 Online Motor Monitoring Drive setup problem Drive or sensor malfunction
Possible Effects: Overspeed trip Overspeed damage Series Poles connected in series have been removed from the circuit
Case II: If >= If_field_weakening Possible Root Cause: Field circuits resistance is lower than nameplate suggests.
Field windings temperature is below standard ambient (40 C) or motor may not have warmed up yet. Series elements of the field winding are not part of the circuit (turn-turn faults) Nameplate vs. Motor issue:
Error entering the nameplate when creating the motor. Motors nameplate doesnt properly represent the field circuit. Possible Effects: If the field circuits resistance is lower than the nameplate suggests:
If the field winding has a turn-turn fault, and if the field voltage has noticeable harmonic components, then the 54
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DC3000 Online Motor Monitoring shorted turns are being overheated. The fields groundwall insulation will fail prematurely. The amount of overheating due to the harmonic current content mainly depends upon the amount of Vf_ripple / Vf. If the ambient temperature is below standard ambient (40 C), and the motor has not operated for a longer time, then the field winding is still in the process of heating up. If the drive does not change the Vf, then If will keep falling until the field winding reaches a steady state temperature. Many drives have motor models used to offer higher quality speed / torque controls. The fields resistance varying too much from the drives motor model may introduce stability problems to speed or torque control. If the motors nameplate doesnt properly represent the field circuit:
Many drives have motor models used to offer higher quality speed / torque controls. The fields resistance varying too much from the drives motor model may introduce stability problems to speed or torque control.
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Armature Voltage Form Factor
Fig 4-3: Armature Voltage Form Factor
Function: Form Factor is defined as:
Va Form Factor =
Va RMS Va Average
This is a representation of how much Va differs from a pure DC signal. The closer Va Form Factor is to 1.0, (the theoretical minimum), the cleaner the signal. Va Form Factor greater than 1.0 indicates AC current components in the armature and could mean more losses. Boundaries The following boundaries apply to DC motors operating from a rectified AC supply. Warning Thresholds: 120%|Va_AC_Line_Rated 56
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DC3000 Online Motor Monitoring 80%|Va_AC_Line_Rated Caution Thresholds: 110%|Va_AC_Line_Rated 90%|Va_AC_Line_Rated Standard: NEMA MG-1 Section 1-12.64 Result: Va Form Factor is Too High: Possible Root Cause Possible Effects: The drives supply introduces excessive variations in the motors armature current. This creates excessive torque ripple for applications defined as essentially torque ripple free. Some applications, for example extruders, do only function properly if the supplied torque is sufficiently constant. An excessive Va Form Factor may cause excessive Ia ripple, resulting in additional commutator sparking. Excessive voltage unbalance feeding the drive. Unsymmetrical firing of the drives armature circuit switches. Drives number of pulses too low.
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DC3000 Online Motor Monitoring Armature Current Ripple
Fig 4-4: Armature Current Ripple
Function: This is current that produces no torque, yet produces heat. Primarily, IA Ripple is the response of the circuit to the armature voltage AC components. The inductance of the motor (and any additional users supplied inductance) can smooth out the armature current ripple at least so some extent. A reduction in the RMS armature current ripple reduces the heating of the motor, while a reduction in peak-to-peak armature current ripple improves the commutating ability of the motor.
Ia Ripple Factor =
Boundaries
( Ia max Ia min ) Ia Average
Warning Threshold: 2.5 < Ia Ripple Factor Caution Threshold: 2.0 < Ia Ripple Factor < 2.5 Standards: NEMA MG-1 Section 1-14.61 58
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Result: Armature Current Ripple is Too High: Possible Root Cause Va Form is too High: Drive Malfunction. Timing of SCRs is Wrong High AC voltage unbalance Armature circuits inductance too small.
Possible Effect The drives supply introduces excessive variations in the motors armature current. This creates excessive torque ripple for applications defined as essentially torque ripple free. Some applications, for example extruders, do only function properly if the supplied torque is sufficiently constant. AC current components contribute more to heating than to torque generation aging the armatures prematurely. Additionally, AC armature current components diminish the commutation capacity.
Machine
The Machine domain displays the issues directly related to the motors health. A machine can be a motor or a generator.
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Fig 4-5: Machine Domain
1. Click on the Machine Domain button. 2. Click on any of the Machine Domain tests to view the Test Results or logs available. Armature Current Level Function: Ia level represents the current flowing through the armature winding.
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Fig 4-6: Armature Current Level
Boundaries: Warning Threshold: 120% Rated < Ia Caution Threshold: 110% Rated <Ia<120% Rated Possible Root Cause Va Level is too high Excessive torque is demanded by the load Armature may have stalled No current in the field Possible Effects Brush Fire Commutator/Brush Damage High Field Resistance Function: Comparison of calculated field resistance as to field resistance at rated conditions.
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Rf =
Vf If
Fig 4-7: High Field Resistance
Boundaries:
R fHot =
V frated I frated
Warning Thresholds: 120% RfHot < Rf Caution Thresholds: 110% RfHot , Rf , 120% RfHot
Result: Field Resistance is too High Possible Root Cause: High temperature 62
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DC3000 Online Motor Monitoring High contact resistance Small copper
Possible Cause Shortened insulation life Low Field Resistance Function: The calculated field resistance is compared to field resistance at rated conditions extrapolated to the lower boundary of the insulation class; See High Field Resistance.
Rf =
Vf If
Fig 4-8: Low Field Resistance
Boundaries:
R f ( cold ) = R f ( hot ) T
Where:
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DC3000 Online Motor Monitoring T = per unit resistive increase for copper going from ambient temperature up to hottest allowable temperature for that insulation class Warning Threshold: 80% Rfcold > Rf Caution Threshold: 90% Rfcold > 80%
Rfcold Result:
Turn-to-Turn Short Field winding is below NEMA ambient temperature (40oC)
Possible Effects: Shortened Motor life Motor was very recently started Ambient temperature is very much below 40oC
Field Current Level Function: If level corresponds to the current flowing through the field winding. Note: It is critical that the field current never falls too low or moves through the zero point, otherwise, the motor could overspeed or stall.
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Fig 4-9: Field Current Level
Boundaries: Warning Threshold: 120% Rated < If Caution Threshold: 100% Rated < If<120% Rated Result: Field Current Level is too High Possible Root Cause: Vf too high Field circuit resistance too low or cold field windings Short in field windings Possible Effects: Too many I2R losses Result: Field Current Level is too Low Possible Root Cause High Temperature 65
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DC3000 Online Motor Monitoring High Contact Resistance Long Leads of small diameter Copper
Possible Effects Overspeed Stalling
Load
The Load domain uses the motor as a sensor to look at the driven load. To fully describe the steady state behavior two components are supplied Torque Ripple: Imaged data short-term behavior as well as load signature. Load Level History: long-term behavior is made viewable.
Fig 4-10: Load Domain
1. Click on the Load Domain to view these tests. 2. Click one either of the domain tests buttons to view the Test Results or Logs available.
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DC3000 Online Motor Monitoring Torque Ripple Torque Ripple is defined as the division of maximal torque divided by average torque during the acquisition period.
Fig 4-11: Torque Ripple
Function: Torque Ripple is a measure of how small the torque band is that surrounds a steady state average torque. The more important feature of this graph is the overall signature of the instantaneous torque (torque versus time plot). This signature is the result of the load requirements of the drive.
T = k Ia If
Boundaries: N/A Results: Torque Ripple is too High A torque ripple in a Ripple-Free application indicates a problem.
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DC3000 Online Motor Monitoring Possible Root Cause Load Problem Drive Problem Load Level Load Level is requested by the load, and the motor has to deliver. If there is a change in the load level, that means that the root cause of that change lies in the driven load, and not in the motors capabilities.
Fig 4-12: Load Level
Function: Load Level history displays the test history of the load. Trending is extremely important, since online monitoring is concerned with identifying deterioration, which in most cases is gradual. A gradual increase of load can be a sign of additional friction in the driven belt system. A decrease can be traced back to a gradual blockage of the inlet of a fan or a pump. Changing loads can only be diagnosed and understood with detailed knowledge of the operating process. Expertise in the particular driven load is necessary to determine whether the change measured is meaningful from a predictive maintenance perspective.
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DC3000 Online Motor Monitoring Boundaries: Warning Threshold: 120%<Load Caution Threshold: 110%<Load<120% In Case Load Level is too High: Possible Root Cause: Load Level problems are always caused by the load. Possible Effects: Overheating
Waveforms
Click on the Waveform Domain button to view the screen below. Waveform shape can be indicative of drive or motor problems. For example, if every sixth peak of the Vf or Va waveform is smaller than the rest, it could mean that one SCR on a sixpulse rectifier is not firing properly (there is no ripple capacitors in a typical DC drive, so these waveforms typically are not flat), and an entire missing tooth in the waveform could indicate a broken SCR. Voltage unbalance should also be visible.
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DC3000 Online Motor Monitoring If should normally be relatively small (high resistance) with less ripple than Ia, because there is more inductance in the field than the armature.
Fig 4-13: Waveforms
Spectrum
Spectra are useful for analyzing the frequency content of timedomain signals. Va, Ia, If, Vf and torque are transformed to the frequency domain with the DFLL (Digital Frequency Locked Loop) and/or the FFT (Fast Fourier Transform). 1. Click on the Spectrum Domain button to view the Spectrum tests. 2. Click on any of the test buttons to view the Graphical Spectrum Test Results.
Fig 4-14: Spectrum Domain
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Field Spectrum Vf and If should have similar spectra at lower frequencies. As frequency increases, impedance also increases (the impedance is mostly inductive), resulting in If spectrum beginning to decrease in amplitude at higher frequencies. The field circuit doesnt interact with the load, so any issues found in the field spectra have to be the result of the voltage sources, the resistance of the field or the inductance of the field. A field circuit powered by rectified three-phase AC should display harmonics at the following locations: DC, 6th, 12th, 18th, There should be no harmonics at multiples of the second harmonic: 2nd, 4th, 8th, The presence of a second harmonic multiple could be due to voltage unbalance at the input of the DC drive. For low ripple applications having excessive If ripple, the inductance of the field circuit could be too low which can be corrected by adding additional inductance externally to the drive and/or motor field circuits.
Fig 4-15: Field Spectrum
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Armature Spectrum As with field, Va, and Ia should have similar spectra at lower frequencies, but as frequency increases, impedance also increases (the impedance is mostly inductive). As a result, the Ia spectrum should begin to
Fig 4-16: Armature Spectra
decrease in amplitude at higher frequencies. Anywhere that this is not the case is due to the machine. The armature spectra is useful in identifying the following problems. Raised Bar Raised Mica Chattering Neutral Plane Problems.
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DC3000 Online Motor Monitoring Torque Spectrum
Fig 4-17: Torque Spectrum
The torque spectrum is composed of both electrical and mechanical components. The electrical component can be reduced by addressing issues enumerated in the sections of this manual pertaining to Va Form Factor and Armature Current Ripple, such as voltage unbalance, unsymmetrical firing of SCRs and insufficient drive pulses. Some applications such as extruders, require very little torque ripple. In these applications it is critical that the ripple be addressed. Once the electrical components of the torque spectrum have been isolated, whatever is left is a mechanical signature.
Harmonics
Harmonics provide an indication of how much alternating current is feeding the direct current motor. When a direct current motor is operated from a rectified alternating current source, rather than from a low ripple source such as a battery, the performance could be affected, possibly resulting in increased temperature and decreased commutation and efficiency. A DC motor operated from rectified three-phase AC should display harmonics at the following locations: DC, 6th, 12th, 18th, 73
70-017 Section 8 16/08/2007
Result The presence of any other harmonic, particularly the 2nd, indicates a lack of symmetry (except for the case of a singlephase rectifier). Unusually large harmonics represent: On Va can indicate an unbalance on the rectified supply Aa blown SCR On Ia can indicate a high contact resistance.
Fig 4-18: Harmonics
1. Click on the Harmonics Domain button to view the graphical images of the harmonics involved with the machine under test. 2. To view the Harmonics in different formats, click on the tabs on the top of this screen to view them. 3. View all four channels or as few as needed by clicking on the check boxes for each channel: IF, IA, VF, VA. 4. Export data in a number of formats. Click on Export and the following screen will appear. This allows this feature to be displayed in several formats, clipped to the clipboard, exported to a file for email, or sent 74
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DC3000 Online Motor Monitoring directly to a printer. Size definitions are also available. The unit of measure is pixels.
Fig 4-19: Exporting Harmonics
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CHAPTER REPORTS
Inside this chapter
Developing and Printing Reports
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Reports
To generate a report, select the test records desired. To select multiple test records simply use the Ctrl or Shift Keys as in any Windows format. Right click and select add to report. If Microsoft Word is open with reports that have previously been generated the new records will be appended to the end of that report. If Microsoft Word is not open it will open a section and display the report.
Fig 5-1: Right Click Menu - Reports
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Explorer DC Electrical Result

Machine Name: Location Test Date/Time Report Date Explorer SN# LINE 2 DART CONTAINER\LINE 2 3/22/2007 9:07:56 AM 8/15/2007 7:08:34 PM $[TESTERSN]$
Nameplate Data: Hp Base Speed [RPM] Field Volts Field Amps Winding
250.00 1750.00 300.00 6.55 Shunt
kW Max Speed [RPM] Armature Volts Armature Amps Insulation Class
186.50 1750.00 500.00 402.00 A
Measurements Average Voltage Max Voltage Min Voltage % Rated Voltage Average Current Max Current Min Current % Rated Current Field 324.84 693.46 -13.95 108.28 6.95 10.23 3.27 106.15 Armature 331.36 658.42 71.27 66.27 306.57 384.23 191.18 66.27 Status Caution Pass Pass Fail Pass Fail Pass Caution Pass Caution Level 31500.00 52500.00 2.00 6.00 42210.00 110.00 90.00 687.75 100.00 Fail Level 33000.00 55000.00 3.00 9.00 44220.00 120.00 80.00 720.50 110.00
Test Field Voltage Level Arm. Voltage Level Arm. Voltage FF Arm. Current Ripple Arm. Current Level High Field Resistance Low Field Resistance Field Current Level Load Level
Value 324.84 331.36 1.33 48.02 306.57 146.01 233.61 6.95 0.00
Notes:
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Explorer - Manual DC

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DC3000 Online Motor Monitoring

DC3000 Online Motor Monitoring

DC3000 Online Motor Monitoring

Users Manual DC3000 DC Online Motor Monitoring Software

DC3000 Online Motor Monitoring

DC3000 Online Motor Monitoring

DC3000 MACHINE ONLINE ANALYSIS SOFTWARE ........................................... 9

SOFTWARE NAVIGATION ......................................................................... 17 DC3000 SOFTWARE NAVIGATION .................................................................. 19

ONLINE TESTING MENU .................................................................................. 30

SOFTWARE TESTING SCREEN ................................................................. 39 SOFTWARE TESTING SCREEN .......................................................................... 41

TEST DOMAINS ............................................................................................. 47

DC3000 Online Motor Monitoring

DC3000 Online Motor Monitoring

DC3000 Machine Online Analysis Software

DC3000 Online Motor Monitoring

DC3000 Online Motor Monitoring

CHAPTER CONNECTION CASES

DC3000 Online Motor Monitoring

DC3000 Online Motor Monitoring

DC Connections for the EXP3000 Portable Sensors:

Fig 1-1: Basic Diagram-Separated Excited DC Motor

DC3000 Online Motor Monitoring

Standard DC3000 Current Sensors has two ranges: 60A/600A 10A/100A Ia If

Fig 1-2 Connection Diagram

DC3000 Online Motor Monitoring

DC3000 Online Motor Monitoring

Fig 1-4: Portable Field Voltage Connection Greater than 500V

DC3000 Online Motor Monitoring

CHAPTER SOFTWARE NAVIGATION

DC3000 Online Motor Monitoring

DC3000 Online Motor Monitoring

DC3000 Software Navigation

Fig 2-1: File Dropdown

Creating a New Database

DC3000 Online Motor Monitoring

Fig 2-2: Create New Database

Fig 2-3: Open Database

DC3000 Online Motor Monitoring

Creating a New Folder

Fig 2-4: New Folder

Create a New Test Item

DC3000 Online Motor Monitoring

Fig 2-6: Create New Machine

DC3000 Online Motor Monitoring

Fig 2-7: Nameplate Information

DC3000 Online Motor Monitoring

Fig 2-8: Validation

Fig 2-9 Validation - Manufacturer

DC3000 Online Motor Monitoring

Right Click Menu Items

Fig 2-10: Right Click Menu

Fig 2-12: Right Click Menu-Properties

Fig 2-13: Create Archive

Restore Archive 1. To Restore an Archive, click on Archive and the Restore.

Fig 2-14: Restore Archive

Fig 2-15: Compress and Send To

Online Testing Menu

Create Dc Test Model

Fig 2-17: Online Testing Menu

DC3000 Online Motor Monitoring

Fig 2-18: Create New Test Model

Edit Test Model