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1. 57 435 1 6293 Fan Vane Pass Graph settings pane I I l 500 1000 Frequency Hz AX 0 000 Hz 0 0 CPM AY 0 000 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 83 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 rere acs ol J bey 4 26 2013 10 28 59AM Gam 7 9 My O Velocity 1 51962 inches per sec RMS 57 435 1 6764 AX 0 000 Hz 0 0 CPM AY 0 000
2. Vibration Pa eed 4 24 2013 4 44 06 PM Time Waveform tab Time Waveform Plot Settings menu items for Time Waveform tab Figure 83 Time Waveform display options A Time Waveform acceleration example display is shown below bm 9 30 2013 7 38 15PM SY A oa Time Waveform Spectrum Trending Displacement Graph Settings Speed 1797 74 Acceleration 1037 438 inches per sec 2 ms AX 0 000 AY 0 00 inches per sec 2 Figure 84 Time Waveform Acceleration 82 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 La 4 24 2013 4 44 06 PM q AA a Me o Velocity K Spectrum tab Displacement Markers Plot Settings menu items for Spectrum tab Graph Settings Figure 85 Spectrum display options Several examples of Spectrum displays follow Vibration by 4 26 20139 3012AM _ Gam 9 e Q Trendi Acceleration 554 37180 inches per sec 2 RMS
3. Speed 1727 75 Acceleration 554 37 Velocity 1 51962 Displacement 0 00450 rs oe 41313 AY 69 60 41390 0 0045001 Foal 01 01 01 11 28 33 A 01 01 01 11 29 00 A 01 01 01 11 29 20 A 01 01 01 11 29 40 A 01 01 01 11 29 50 A Figure 93 Trending Displacement 88 Dynamic Motor Analyzer EXP4000 User Manual aKF Vibration software option Speed 1727 75 Acceleration 554 37 Velocity 1 51962 Displacement 0 00450 a O oN 41390 1727 7 CIEE VSE 1710 l l l l l 01 01 01 11 28 33 A 01 01 01 11 29 00 A 01 01 01 11 29 20 A 01 01 01 11 29 40 A 01 01 01 11 29 50 A Figure 94 Trending Speed Tools to enhance viewing graphs You have many options available to you to help inspect your graphs more closely Zoom features help you enlarge specific sections of the display as described below e Zoom Click and hold the left mouse button then drag the cursor to define the area to zoom in on As you drag the cursor a line shows the area that will be enlarged when you release the mouse button e Zoom X axis only Click and hold the left mouse button and drag the cursor parallel to the X axis Vertical guide lines will show the portion of the X axis that will be zoomed In on e Zoom Y axis only Click and hold the left mouse button and drag the cursor parallel to the Y axis Horizontal guide lines will show the portion of the X axis that will be zoomed In on e Undo Zoom Press the Space ba
4. 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 la 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 Va gt f f il ae VAs iis SN MS 4 F E a Vib T 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 18 Dynamic Motor Analyzer EXP4000 User Manual aKF 5 EXP4000 tests Test domains and testing theory The EXP4000 utilizes a multitude of tests to determine the power co
5. 2 Type in the appropriate machine name and click DC machine 3 Click on the Next button to continue the process Figure 105 Create test item wizard You can type values directly in the fields or use the dropdown lists when available to make your selections Notice that required fields appear in bold type wo w 20 Mex Speed RPM BD Armature Volts 000 Amature Amps Number of Poles 2 Number of Commutator Bars ros neos rane Field Weakened Volts 0 __ Service Factor Enclosure Max Ambient Temp C ec vekte gt Sip vaan gt gt Gann i Ip Figure 106 Create Machine window entering nameplate information e Number of poles 2 4 or 6 e Has interpoles yes no e Winding chooses between shunt compensated shunt or permanently excited e Insulation class A F B or H e Number of commutator bars this is a display with an up down arrow with progressive values in multiples of two Required fields are listed in bold Yellow fields are recommended but may be left at default values After all information is entered click Finish to add the machine to the list in the Machine Tree aKF Dynamic Motor Analyzer EXP4000 User Manual 97 DC4000 software overview Using the icons toolbar for feature access alternatives Some of the features accessed from the File and Tools menus can also be accessed via the icons found in the toolbar just above the Navigation Pane These features are identifi
6. Fald Piea Colfi Caution pm ET a20 ang bet O Figure 134 Low Field Resistance Typical thresholds Where Delta T per unit resistive Increase for copper going from ambient temperature up to hottest allowable temperature for that insulation class Warning threshold 80 Rfcold gt Rf Caution threshold 90 Rfcold gt 80 Rfcold DC machine low field resistance troubleshooting Result e Jurn to turn short e Field winding is below NEMA ambient temperature 400C Possible effects e Shortened motor life e Motor was very recently started e Ambient temperature is very much below 400C aKF Dynamic Motor Analyzer EXP4000 User Manual 119 DC4000 software overview Field Current Level Function Field current 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 over speed or stall Figure 135 Field Current Level Typical thresholds Warning threshold 120 rated lt If Caution threshold 100 rated lt If lt 120 rated DC machine If troubleshooting Result Field current level is too high Possible problem root cause e Vf too high e Field circuit resistance too low or cold field windings e Short in field windings Possible effects e Too many I2R losses Result Field current level is too low Possible prob
7. 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 40 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 Symmetrical Components Amplitude Phase Unbalance Amplitude Phase veo 02m oo vai e007 oo wo sam Cor ve 20 r veo osm Dar B w2 es ue za C aer z Lot Lies 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 Phase values dependent on proper sensor connections Figure 31 Phasors within the Connection domain aKF Dynamic Motor Analyzer EXP4000 User Manual 41 EXP4000 tests 42 Dynamic Motor Analyzer EXP4000 User Manual aKE 6 EXP4O00O0 software overview
8. 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 _ EZ v E o Figure 57 Efficiency vs Load operating curve display Figure 58 PF vs Load operating curve display 60 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 Speed Overnde 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 61 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
9. 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 Machine Thresholds Tools Help New Ctrl N Report Generator Ctrl F2 Open Ctrl O Summary Repot Ctri P Close 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 f 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 EXP
10. 46 Dynamic Motor Analyzer EXP4000 User Manual aKE 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 Machine Properties us Name NEW AC Machine 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 Use the Tab key on your keyboard to move between the fields in the Name Plate tab and enter values for each required field Enter values in other fields to provide more resolution and to improve report quality 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 Check the VFD box if the motor Is being driven by a variable frequency drive device 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 47 gz 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 volta
11. Figure 87 Spectrum Velocity 84 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 E SKF 10413 BPFO ers SKF 10413 BPFI 7182 01 10 305 SKF 10413 BSF 420 51 26 451 AX 238 504 Hz 14310 3 CPM AY 16 146 Figure 88 Spectrum Displacement aKF Dynamic Motor Analyzer EXP4000 User Manual 85 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 Markers Pane Select Marker Type dialog het teeta a zrei Fore ira Pore TF iHi Bee J F IHG RTF Figure 89 Setting marker types and harmonic settings To set the Harmonics setti
12. Setting gauge and graph scales 1 2 Hover the mouse cursor over the object you for which you want to define scales then right click the mouse 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 Set the values for scaling as needed then click OK Scale b A AutoScale N Channel d Manual Mowe Figure 76 Scale menu item AutoScale aKF Dynamic Motor Analyzer EXP4000 User Manual 75 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 Scale IA RMS A Channel IB RMS A IC RMS A VA RMS V VB RMS V VC RMS V v TAvg RMS A V Avg RMS V I Imbal 9 V Imbal 9 IA Angle deg IB Angle deg IC Angle deg VE Angle deg VC Angle deg ZA Angle deg ZE Angle deg ZC Angle deg Z Angle Avg deg Power A kW Power B kW Power C kW Total Power kW Figure 77 Channel menu 76 Dynamic Motor Analyzer EXP4000 User Manual aKE Continuous Monitoring Softw
13. User manual SKF Dynamic Motor Analyzer EXP4000 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 970 282 1200 970 282 1010 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 US04 7 68380 e US05679900 e US05845230 e US05854553 e US05992237 e US0
14. Eas Deben a teak bo perkcers E Coles EP A im EP Satire lees LT gree Figure 53 EP Calibration Wizard 58 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 Looped Acquisition Number of Tests to Run 10 Run Until Manually Stopped EO Make this my default setting 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 rare Curent Time 4 22 2013 10 38 05 PM Electical Test s ma 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 59 EXP4000 software overview Operating Curves
15. Motor is running at no load yet Autophasing failed rare Turn autophasing feature off EXP4000 is displaying high Ensure proper phasing In load connection Save data and send to SKF support for further tuning of autophasing feature N N Frequently asked questions The EXP4000 shows the wrong speed It displays the operating speed as synchronous speed 3600 1800 1200 900 rpm and so on for 60Hz operation or 3000 1500 1000 rpm and so on for 50Hz operation However the motor is running at speeds lower than that What is the problem When creating a new machine the nameplate speed needs to be entered into the Speed RPM field in the Machine Properties dialog box If the synchronous speed was entered the EXP4000 expects to be testing a synchronous machine not an induction machine For a synchronous machine displaying the synchronous speed is correct 1 To edit the properties click on the Machine menu then Machine Properties 2 f desired enter a new name in the Name field 3 Click on the Apply button A confirmation dialog will pop up saying Machine Name has changed Create a New Machine 4 Select No to update the existing machine 5 Clicking on Yes will create a new machine 6 All nameplate fields will now become editable Make changes as appropriate and click Apply This will create a new machine without any test data 7 To view this new machine click on its name in the Machine Tree 8 Y
16. Standards NEMA MG 1 Section 1 12 64 aKF Dynamic Motor Analyzer EXP4000 User Manual 109 DC4000 software overview DC machine Va troubleshooting Result Va gt Va nameplate Possible problem root causes e Drive settings and motor nameplate data do not coincide e Drive or sensor problem e Malfunctioning control circuit or feedback e Neutral plane is off Possible effects e Operates over rated speed motor e Brush fire Excessive brush sparking due to armature over voltage e Commutator brush damage Field voltage level Vf Function Connecting field voltage Vf onto the field winding causes the flow of field current If This creates the magnetic field necessary for torque generation liri Vinee Lael Figure 128 Field Voltage Level Typical thresholds Nominal Vf_field_weakening lt Vf lt Vf_base_speed Warning Thresholds 120 Vf_base_speed 80 F_field_weakening Caution Thresholds 110 Vf_base_speed 90 VF_field_weakening Standards NEMA MG1 Section 1 12 64 110 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview DC machine VF troubleshooting Result Vf gt Vf_base_speed Possible problem root cause Case If lt f_base_speed e he field circuits resistance Is higher than nameplate suggests e he field winding is running too hot e Excessive contact resistance in the field circuit e he field circuit s lead lengths cause additional
17. 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 12 Use the plus and minus Icons to the left of tree elements to locate the machine that you want to test 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 Ensure that the EXP4000 is properly connected to the machine Press Run Electrical to start testing and data collection Alternatively you can click on the Tools menu then the Run Electrical item Bp Surveper EXP AC versions 3 121 Fla Michi Thiab Took Haig OSS ROS DE 1271 PA sign 97 2019 0208 0 a Curent E oaa EFH ania SN V Unbal 1 Unial Selected machine appears in Machine information bar gi La i agg Ik l Machine tree CTs Figure 4 Machine tree used to find files and folders for testing Dynamic Motor Analyzer EXP4000 User Manual aKF 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
18. can be made This dialog rarely pops up 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 lat lb lc lg 0 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 Cls hoon Phase bep bot Map To i ma A EL S80 feo amma Bee Figure 6 Connection Setup window indicating connections need to be checked Figure 7 Connection Setup window indicating connection are good aKF Dynamic Motor Analyzer EXP4000 User Manual 17 Connecting the EXP4000 Manual phasor adjustments Manually adjusting the phasors can guickly 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
19. 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 the undersigned hereby declare that the equipment specified above conforms to the above Directives and Standards Signature Se Printed Name ErikA Stolz Title Electrical Engineer aKF Dynamic Motor Analyzer EXP4000 User Manual ili Notices Software License Agreement UNI T 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 desk
20. 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 e F1 key on the keyboard opens the loaded Help environment e F2 key opens the machine properties e F3 key operates the New AC Machine function e F5 key operates the Run Electrical function e F key opens the Virtual Scope feature e F8 key displays the View Connections function e F9 key operates the Transient Analysis Dialog e Ctrl A About e Ctrl M User Manual e Ctrl O Open Database e 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 b
21. R 0 5 1A lt 2 5 of R 10 80A 1 of R 10A lt 3 of R 0 2mV 1 10A lt 1 of R 50A lt 1 5 of R 80 150A 1 5 R 0 2mV 200A lt 0 75 of R 1000A lt 0 5 of R Weight 3 x 180g 3 x 180g 3 x 550g pS 139x51x30mm 139x51x30mmea 111 x216x45 ea mm ea 156 Dynamic Motor Analyzer EXP4000 User Manual akr Table 8 DC current transformer CT specifications 10A 100ADC 60A 600ADC 4000A 7500ADC Output 10A 100mV A 60A 10 mV A 4000A 2V 100A 10mV A 600A ImV A 7500A 1 5V Measurement 100mA 100A 0 2A 600A 40A 7500A Range Overload Red LED indicates 2000ADC continuous overload up to 1 kHz Working Voltage 600Vrms 600Vrms 600V Accuracy 50mA 10A 3 of R 60A 1 5 50mA 0 5 40A 1 5 of R 0 5A 500mA 40A 4 of R 50mA 40 60A 1 5 of R 4QA 100A 15 max 600A 100A 0 5 100A 1 5 of R 1A 100 400A 2 of R Weight 25 s 231x36x67 mm 224x97 x44 mm 13 23 x54x 20 inches Table 9 Connector specifications aKF Dynamic Motor Analyzer EXP4000 User Manual 157 158 Dynamic Motor Analyzer EXP4000 User Manual aKE Index A Accessory Interconnection and use 5 Acquire EP Serial Number 50 Acquisition tab 63 Adding a new gauge or graph 74 Adjusting electrical acquisition time 133 Adjusting parameters 132 Armature Current Level 117 Armature Current Ripple 114 Armature spectrum 126 Armature voltage form factor 113 Armature voltage level Va 109 Arrows and windows icons 8 Assigning an E
22. 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 for
23. VOLTAGE_LEVEL Figure 154 Select Results window 4 Use the Filter On menu to filter the displayed results by result status or by a specific data range Filter On Select Trending n Show Good Results Show Caution Results Show Warning Results Date Range Figure 155 Select Results Filter On menu aKF Dynamic Motor Analyzer EXP4000 User Manual 135 Example test and report generation 5 Click on the Select menu to select the displayed results for reporting based on result status Filter On Select Trending On All All Good All Caution All Warning All Warning and Caution h Figure 156 Select Results Select menu 6 Click on the Trending On menu to view trending parameters By clicking on the words Trending On the filtering parameters for the menu toggle on and off Select Results Selected Results Onh Plot Mode Figure 157 Select Results Trending On menu 7 Click on OK after all parameters for the report have been developed The report wizard will now create the report you can save itas a rtf type file It can then be reviewed in an assortment of software 8 A window appears to select the location for the report Enter the name and select the proper location then click Save The software will create a Rich Text Format rt document and automatically open it in your default text editor program This document can be edited to suit your needs fo
24. a database click File and Open Database A new window appears like the one shown below 2 Choose the appropriate database then click Open The database opened will be the active database used by the software Uen merted rypa Li Le NA Fieis ied lhe H WOL le Figure 102 Window used to open database aKF Dynamic Motor Analyzer EXP4000 User Manual 95 DC4000 software overview Closing a database To close a database click File then Close Database The database is automatically saved when you close it Creating a new folder To create a new folder click File then New Folder the new folder will be added to the Tree View File Online Testing Tools Help D Ge EF N el Mot4nal H E BASEMENT EES CLASSIC PROBLEMS aes CLASSIC PROBLEMS 5 TEI Figure 103 New folder Renaming a folder To rename a new folder right click on the new folder and then on Rename in the dropdown box The software will place a box around the new folder Type in the appropriate name and press enter or click outside the folder File Online Testing Tools Help Oae 2 Bw le MMot4nal H E BASEMENT SE CLASSIC PROBLEMS H E CLASSIC PROBLEMS 43 DC Machine Figure 104 Rename folder 96 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview Creating a new test item 1 To create a new test item click File then New Test Item A wizard will appear to lead you through the process of creating a new machine
25. and Statics of Electromechanical Energy Conversion McGraw Hill 1961 New York Toronto London second edition 8 Wiedenbrug Measurement Analysis and Efficiency Estimation of Three Phase Induction Machines Using Instantaneous Electrical Quantities Dissertation submitted to Oregon State University September 24th 1998 9 Buscarello Practical Solutions to Machinery and Maintenance Vibration Problems Revised Edition Update International Inc 1997 10 O Flynn Moriarty Linear Systems Time Domain and Transform Analysis Harper amp Row 1987 ISBN 0 06 044925 11 Luke Signallibertragung Grundlagen der digitalen und analogen Nachrichtenubertragungssystheme Springer Verlag third edition 1988 ISBN 3 540 19435 5 12 Gabel Roberts Signals and Linear Systems John Wiley and Sons second edition 1980 ISBN 0 471 04958 1 13 Karni Byatt Mathematical Methods in Continuous and Discrete Systems Holt Rinehart and Winston 1982 ISBN 0 03 05 7038 Glossary of terms Average Power Factor Average of three single phase power factors Clampons Split core clamp on CT s Clipons Clips for voltage pickup Crest Factor Difference between the sine wave peak and the RMS value Current The time rate of flow of electric charge in the direction that a positive moving charge would take and have magnitude equal to the quantity of charge per unit time measured in amperes Efficiency Defined as output
26. 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 35 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 freque
27. degrees This number will typically vary between 90 degrees at no load to 20 degrees at full load for induction motors 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 78 Dynamic Motor Analyzer EXP4000 User Manual aKE 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 AX 0 000 AY 0 00 a Faia ae TERE EE l l l l I 0 1 2 3 4 6 7 8 9 en ne no iio ld et E ay al RR eeeeeeeeeee 1000 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 Run Vibration icon Test Selection dropdown Plot Settings icon Vibration Gain Multiplier icon Display selection tabs NextPrevious Record Export Data icon Help icon selection arrows 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 tes
28. eree e cacaseeests antes Looking at data COMESCLE ca cancsscevesseeseovaonsssdeivocsemesvouveasssuecdbeuaunesecses Creating reports from the report generator eeesesesseseeseeseesese Automatic generation Of repor tS sesssesseesessessesresreseseesresessessesses Appendix A Default settings PE Te SECC G Soe cecoeersesdeastaecacenesneasact nensis a Ea aa Appendix B Connection troubleshooting CSN OA EEEE AAEE T EE PV TF TOO neurean T E Frequently asked questions i csssssevudsacsnconssevesayiariauenssrsinabesiosensbuebbariare Appendix C Blue results Appendix D EP4000 installation Safety precautions for EP installation seseeseseeseeseeresrserssessresessess Choosing a suitable location for the EP woe ccs cesceeeeees FO TIUN oien AE Appendix E References and glossary ELNE E aa e A E Literature o oo eececccsssscccccccsseescssccccccceseescsscccccccsseeesssaccccceseeeestssccceeseceeens Cokie pV gre E ener A E eS Appendix F Technical specifications Index aKF Dynamic Motor Analyzer EXP4000 User Manual 131 131 12 139 136 137 137 139 139 139 140 143 145 145 146 147 150 151 151 1o 152 155 159 xi Table of Contents xii Dynamic Motor Analyzer EXP4000 User Manual aKF 1 About this manual This manual uses the following conventions in formatting and informational devices to help you more clearly identify specific elements and informatio
29. it Is installed Installing a fuse block near the EP connected in line between the EP and the voltage source is recommended Ensure there is enough wire length to connect to the EP Electrical connections Once the EP has been mounted CTs have been installed and three phase voltage lower than 1 000 VAC is made available the electrical connections may be made 1 Connect the three CT twisted pairs to the EP current terminal block corresponding to the appropriate phase marked la Ib and Ic from right to left white wire on the right and black wire on the left for each phase Tightening torque is 0 5 N m 2 Connect the three voltage leads to the EP voltage terminal block corresponding to the appropriate phase marked Va Vb and Vc being sure to connect a ground to the ground position of the voltage plug Tightening torque is 9 in lb Additionally the MCC ground should be connected to either of the ground studs on the EP enclosure 3 Mount the cover over the top of the voltage terminal block by either using the supplied screws and nylon spacers plexiglass cover only or by snapping in place For the plexiglass cover the screws thread directly into mounting holes in the EP case 0 437 inches above and below the top and bottom voltage terminal block mounting screws respectively 4 Connect the MCC cable the end opposite the panel plug to the A D Bus DB25 receptacle of the EP and secure In place with the captive screws 5 Prov
30. 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 aKF 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
31. must comply with the following safety precautions e Comply with your facility s safety practices at all times e 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 e 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 e Ensure that appropriate lockout tag out procedures are properly understood and implemented by all personnel e Every connection at MCC must be performed ONLY when rotating system Is powered down or off e 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 e Do not position motor phase connections near ground or near each other e Do not touch the connections PT s CT s or any component under test while a test Is being made e This product is grounded through the grounding conductor of the power cord if running on AC power e Voltage ground clip must be connected to ground when the unit is running on battery power e fyou will be running the unit on battery power ensure that you remove the power c
32. needs to be monitoring the SUM of both currents and not the subtraction This means that the orientation of the wires through the CT has to be such that the currents add and do not subtract If the wires are set such that the currents subtract the EXP4000 will monitor a very high current unbalance through that CT If this is the case take one of the two wires out of the CT and introduce it into the CT in the opposite direction with respect to the CTs arrow aKF Dynamic Motor Analyzer EXP4000 User Manual 141 142 Dynamic Motor Analyzer EXP4000 User Manual aKE Appendix C Blue results Blue results are results that have no threshold comparison but give valuable information about the machine Table 5 Conditions under which tests show blue results Voltage Level Always for VFD mode never in non VFD mode Efficiency No entry of stator resistance No comparable motor found in database Payback Period Efficiency blue condition Missing data of a lest one of the following Hours per day Days per year per kWh Current Imbalance Load lt 25 144 Dynamic Motor Analyzer EXP4000 User Manual aKE Appendix D EP4000 installation To obtain complete installation drawings and templates please contact Baker Instrument Company an SKF Group Company and ask for document number 71 028 What to do first Please verify all needed materials are in package e EP4000 e 3CTs e Terminal block cover and har
33. 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 Click on Create Test Model 3 Type a name for the model in the Test Model Name field 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 Create Test Model Test Model Name New Test Model Caution Level Over Voltage X 110 00 Under Voltage 95 00 Voltage Unbalance gt 7 00 Harmonic Distortion V 7 00 Total Distortion V 3 Current Level 3 Curent Unbalance Z Load Hf Service Factor 1 10 Rotor Bar Amplitude db 45 00 Pattem Difference 20 00 Payback Period months 60 00 Figure 43 Create Test Model dialog box 52 Dynamic Motor Analyzer EXP4000 User Manual aKE EXP4000 software overview Edit Test Model Clicking on the Edit Test Model menu item re opens the Select Jest Model dialog box so you can select the model to edit After selecting the model and
34. power divided by input power Electrical Model A group of Electrical thresholds EP External Port Harmonics Periodic motion consisting of one or more vibratory motions that are symmetric about a region of equilibrium as the motion of a vibrating string of a musical instrument Haystack Name of the NEMA guideline to Vibration Speed versus Frequency in a double logarithmic scale Horsepower A foot pound second unit of power equivalent to 550 foot pounds per second or 745 7 watts Kilowatt A unit of power equal to 1000 Watts Load What the motor drives MCC Motor Control Cabinet Motor ID Unique name tot he motor to be tested NEMA Derating Factor Factor between 1 and 0 Displays how much a motor has to be derated according to NEMA to accommodate for sub optimal voltage conditions NEMA Unbalance Number commonly defined in percent according to an algorithm specified by NEMA Displays how much of relative unbalance is part of the voltage condition Newton Meters Metric unit of torque Overcurrent Measure of operating current in percent comparing to the motor s nameplate Phasors A vector that represents a sinusoidal varying quantity as a current or voltage by means of a line rotating about a point in a plane the magnitude of the quantity being proportional to the length of the line and the phase of the quantity being equal to the angle between the line and a reference line Pound Feet English system Power Fa
35. respective owners aKF Dynamic Motor Analyzer EXP4000 User Manual vil Notices vill Dynamic Motor Analyzer EXP4000 User Manual aKF Table of contents 1 About this manual 1 FO BIG CUMING ea vents vances desu vies cosiausevsaccanspasrasseossadeacterianasec E 1 Wa POINT UCC WCNC A secenaysouepoteeredesaceerudeseuseseeuetvonaeneenneaneuee 1 2 Safety and general operating information 3 Generi salet CC a CIO secsgerionononorinianona o dinni nenen e aiaia Naa 3 Symbols and labels Used ON CQUIDMENL uve eee sce ccssccsscescesscssscssssssscssssssscsssesseeseeeseees ES VN Oo E E EE 4 Operatonal sae AAI oeenn onid nra aen Eaa EE a ee 5 Accessory interconnection and USC seesesssssessesseseesessessessesresresresresresrestesresessrestssesresressesns 5 Cleaning and decontaminatiO Vea coeesnesaasicasacudeedieraseanvseeserscesiavaiastuscauatesntesaeivansbesssatendeaseavsnesnes 5 A SEO reremen cinia nna ene a a a i 6 Environment CONItIONS StOTAGE karereanana a EE E EES RO ANEA RTN 6 Eio al INEC ETa EEE E AA E E ENEE EA O ee a A 6 SAO CRS UII a E aconcigseaonisassaesennsencarcaesats 6 3 Getting started 7 Configuring software for motor data eseeseeseesessessessessesesressesresressesresresresresresrerrsressesns 7 Bevel acto ml ercl 0 ot ee E ee ee A as ee ee T nee ee 7 EXP4000 software specific features seseseeseesessesseseesessessessessessessessesresrssresrssrsressessesses l tarung Me SoN IC serseri Ea a a EESE EEE EIN IR EEEE i
36. 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 62 Dynamic Motor Analyzer EXP4000 User Manual aKF EXP4000 software overview Acquisition tab The Acquisition tab is used to select how the electrical data Is collected Hectrcal Acquisition Options Aoa Tine fe Hamonics to Save I Min Frequency Hz 10 kai Max Feguency a Spectrum Acquisition Options hea Tine peci F Max Hz 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 63 EXP4000 software overview Help menu The Help menu provides access to several information resources to help you learn how to use the product more effect
37. 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 57 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 F7 Continuous Monitoring V2 View Connections Fe Looped Acquisition a Mode e i Auto Assign he aoe eee Lease Do Not Assign Operating Curves Cache Only Raw To CSV Speed Override Test Notes Options 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 Welcome to the EP Calibration Wizard Tha ptineed yell pio pou fo pete a aia of your EP ung the portable peo
38. the voltage phasor of phase A in degrees This number is Zb angle degrees away from Vb angle IC Angle deg Angle between the current phasor of phase C with respect to the 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 77 Continuous Monitoring Software option 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
39. used during line operation to set up the line and current inputs e 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 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 1 Chics on teal domain LO_ErPA Gest 425 De ST OL maHa wiy onl Yy i Ss WK aS Are Pr fas Aeepitudes i 79 ll ma iI 718 I me Aen pr 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
40. voltage drop prior to reaching field winding terminals e Error entering the nameplate information when creating the motor Possible effects e Contact resistances tend to increase over time Following this trend the worsening contact resistance will lead to over speed trip or over speed damage to the motor e The field winding s resistance varies too much from the drive s motor model which may introduce stability problems to speed or torque control e On inexpensive motors with no speed control the motor can overspeed possibly causing damage e Field lead lengths cause additional voltage drop prior to reaching field winding terminals e Many drives have motor models used to offer higher quality speed torque controls The field s resistance varying too much from the drive s motor model may Introduce stability problems to speed or torque control Possible problem root cause Case II If gt If base e Drive setup problem e Drive or sensor malfunction e Short in field Possible effects Many drives have motor models used to offer higher quality speed torque controls The field s resistance varying too much from the drive s motor model may Introduce stability problems to speed or torque control Results Vf lt Vf_field_weakening Possible problem root cause Case I If lt If_field_weakening e Drive setup problem e Drive or sensor malfunction Possible effects e Over speed trip e Over speed da
41. 0Hz or 50Hz line operated and VFD Variable Frequency Drive mode The connection requirements for each of these modes differ slightly For VFD connection troubleshooting refer to chapter 7 VFD anaylsis software option Non VFD mode This mode is operated in two different ways with or without autophasing Autophasing allows for automatic correction for proper phasing of the current transformers CTs with respect to the connected voltage phases The autophasing feature is designed to recognize which CT signals belong with which polarity and to which connected voltage signal It requires that the observed three phase load be only an induction motor without power factor correction downstream of the point of connection If any other device is being observed the autophasing feature needs to be turned off Table 4 Non VFD issues causes and actions with autophasing feature turned on Monitored speed is wrong The device connected is either Turn the autophase feature off not a three phase induction and be aware that portions of motor or there are power factor the data ind speed torque correcting capacitors down the rotor bar efficiency will be line from the point of compromised connection Motor Is running at high load Autophasing failed rare Turn autophasing feature off yet EXP4000 Is displaying low Ensure proper phasing in load connection Save data and send to SKF support for further tuning of autophasing feature
42. 1b and IEEE 802 1149 Power Voltage requirements 110 230Vac 50 60Hz RAM instal 512 MB uporadesbieto 268 Video Maximum resolution external 800 x 600 pixels Sensors Current transformer clamp on Hall effect 60 600A DC 10A 100A DC 4000A 7500A DC Current transformer clamp on 10A AC 150A AC 1000A AC Current transformers 3000A AC AC voltage clips 1000V DC voltage clips Vibration probe with magnet optional Grounding clip AC Voltage Clips One set of three voltage clips plus one ground connection color coded Maximum rated voltage 1000V DC Voltage Clips Set of four color coded Maximum rated voltage 500V Vibration Sensor Sensitivity 100m 20 optional Acceleration range 50g peak Amplitude non linearity 1 gt Frequency response 1 6Hz 7kHz 10dB Connector MIL C 5015 Splash proof cable Rare Earth mounting magnet Dust proof crush resistant Dimensions 15 11 x 12 40 x 6 94 inches Power Supply Input voltage 100 240Vac Requirement eS Input current 3 0A ee Input frequency 50 60Hz Table 7 AC current transformer CT specifications Current Clamp 10A AC 150A AC 1000A AC 3000A AC On Output Signal 10A 1V 150A 1 5V 1000A 2 5V 0 3 mV A Measurement 01A 10A 01A 150A 1A 1000A 5 3000A Range 600V RMS 600V RMS 600V RMS 1000V Jaw Dpenin Accuracy 0 1 0 5A lt 2 5 of 0 1 1A 2 0 0fR 0 1 10A lt 3 R Reading R 0 1mV 0 2mV 0 1A of
43. 4000 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 Select Results Filter On Select Trending On BT scr of Basement S E i ciassic PROBLEMS 2 cussic proetems n A BAD_ROTOR_BAR 9 CT_BAD_ROTORBAR F INCIPIENT_ROTOR_BA Fa LOW_EFFICIENCY Fo MILD_ROTOR_BAR OVER_CURRENT Fe OVER_CURRENT_ESF ROTOR_BAR Ey VED_VOLTAGE_DIST Fy VOLTAGE_LEVEL Figure 33 Select Results dialog for generating reports The EXP4000 software generates an rt f 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 44 Dynamic Motor Analyzer EXP4000 User Manul gt SKF EXP4000 software overview Summary Report Thi
44. 46 Safety warnings 4 Scope 54 Select Marker Type dialog box 86 Select Test Model 51 Sensor Ratios dialog box 48 set the Harmonics settings for a marker 86 Setting gauge and graph scales 75 Setup wizard suggest button 16 Shipping the unit 6 Software testing screen 105 Software tips 13 Spectrum 125 Spectrum Acquisition options 133 Spectrum Displacement 85 Spectrum domain 33 aKF Index Speed Override 61 Starting the software 8 Summary Report 45 Symbols and labels used on equipment 3 Symmetrical Components Sym Components 41 T Technical specifications 155 Test domain buttons 10 Test domains 108 Test domains and testing theory 19 Testing capabilities 19 Test Notes 61 Text fields 7 Thresholds menu 51 Tools menu 54 70 103 Tools to enhance viewing graphs 89 Torque domain 37 Torque ripple 122 Torque Ripple Result tab 37 Torque Ripple Trend tab 38 Torque spectrum 127 Torque Spectrum 39 Total Distortion 23 Transient Analysis 56 Trend tab 11 Trigger parameter descriptions 73 Two CT solution 17 U Unpacking the unit 6 Upgrading databases from previous software versions 13 Using looped acquisition 102 Using the Icons toolbar for feature access alternatives 98 V Verification of installation 149 VFD4000 analysis software option 65 VFD Details domain 67 VFD mode 65 Vibration 59 Vibration software option 9 View Connections 55 View Connections button 107 Viewing properti
45. 6006164 e US06199422 e US06202491 e US06275781 e US06489884 e US06513386 e US06633822 e US6 789 025 e US6 792 360 US 5 633 811 e US 5 870 699 e WO_03_048 14A1 Notices A 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 Itis 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 SKF Notices CE Declaration of conformity Manufacturer s Name amp 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
46. 80 270 4 W h mn Ay e M it si 36 34 0 4 5 Frequency a Figure 65 VFD Details window aKF Dynamic Motor Analyzer EXP4000 User Manual 67 68 Dynamic Motor Analyzer EXP4000 User Manual aKE 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 7 a Continous Monitoring File Machine Tools View Options Help VA RMS VB RMSM VC RMS M 2 00 4 00 6 00 3 09 2 00 4 00 6 00 3 o9 209 400600 ang 0 00 10 00 0 00 10 00 0 00 10 00 0 00 0 00 0 00 00 05 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 IA RMSI A IB RMS A IC RMS A 0 00 10 00 0 00 10 00 0 00 10 00 0 00 0 00 0 00 l 1 1 1 l l 1 1 l 1 l 1 1 l 0 0 0 5 1 0 1 5 2 0 25 3 0 3 5 40 45 5 0 55 6 0 6 5 7 0 7 5 8 0 8 5 9 0 95 10 0 4 n 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 databas
47. Analyze troubleshoot load issues e Analyze troubleshoot I2R issues e Assists in setting neutral plane A A DC4000 software overview DC connections for the EXP4000 portable sensors DC sensor voltage ratings Terminology Va Armature Voltage Vf Field Voltage la Armature Current If Field Current l Field Armature Figure 95 Basic Diagram separated excited DC motor Connection cases Current sensor connections 1 la lt 600A If lt 100A Standard DC portable sensors Standard DC4000 current sensors have two ranges 60A 600A la 10A 100A_ If 2 600A lt la lt 15 000A orlf gt 100A Optional DC portable sensors Optional DC current sensors are available extending the current range above 600 A for the armature and or above 100 A for the field 92 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview L Field i ARM ature Figure 96 Connection diagram portable Voltage sensor connections V lt 500 V The EXP voltage connection is made directly across the armature voltage or field voltage The graphic below shows the field voltage connections Field Portable Field Figure 97 Portable field voltage connection less than or equal to 500V V gt 500V If the DC motor s voltage exceeds 500 V then a resistive bridge can be used to supply a lower proportional voltage to the EXP4000 The graphic below shows this done for the field voltage c
48. E E set N E 66 YPU DEEI ON ea iE A E EAEE 6 8 Continuous Monitoring Software option 69 FUME TN ac sats teaccacr E E E A A E A 70 MACAE TNE U E AE E EEE E EE 70 TOS N e 70 ONTE E E E 71 OPU NS eea E E E E E A 72 OTC aS aU OT CONS sisseseade 73 Modifying tie continuous MAOTITONMING WOO erzeccicacaaccdasensersesecossbenanssiactiataxecseantessagesiecsastars 74 Glare lelaie deS gl aid 0 y ic eea Mer nere mene nee name nr rene Oe nny wn eT E 71 9 Vibration software option 79 VANO O a occa E E A E seen vervens sats 82 Tools to enhance viewing graphS eseseesessesessessessesesseesessessesresresresresrestssrsstsnreressessessesres 89 10 DC4000 software overview 91 DC4000 Machine Dynamic Analysis software tests and features oo eeeeeeeeeees 91 DC4000 Machine Dynamic Analysis software problem types identified wo 91 DC connections for the EXP4000 portable Sensors eee ceescsescetsssscssesssessseeeens 92 DC4000 software navigation and OVETVICW essssssssssssssseesessessesresessesresresresessesresresese 94 Software testing SCreen ame Ren ene nnE neat ene ee ee en 105 MSE COW NG E RE EE E A A A E A OS AT 108 x Dynamic Motor Analyzer EXP4000 User Manual akr Table of Contents TOPE FUNC sc ecec ce ecatecees OO E Load eVel srecni E S E E TAEA A E AN A E SPECUUNN scacesamavosessm ascinsctsatlnusocasiana EEEE OSEI EEEE ERRER A ENAS PANO reves ects E EE T ROTOT E rs araaenadentenaeees 11 Example test and report generation KOOTAAN OINO
49. P toa motor 49 Automatic generation of reports 136 B Blue results 143 Bottom of main screen 107 C Calibrate EP 58 Center of screen 106 Channel descriptions 77 Choosing a suitable location for the EP 147 Choosing a suitable location for the panel plug 148 Cleaning and decontamination 5 Closing a database 96 Index Configuring software for motor data 7 Connecting the EXP4000 15 Connecting the EXP4000 to the MCC 15 Connection domain 40 Connection Setup window 16 Connection troubleshooting 139 Consequences of not organizing data into databases Continuous Monitoring Software option 69 Create Test Model 52 Creating a DC test model 100 Creating anew database 95 Creating a new test item 97 Creating reports from the report generator 135 CT selection 105 Current domain 31 Current Level 31 Current Transformer CT connections 148 Current Unbalance 32 D Database 43 Database features Database management DC4000 Machine Dynamic Analysis software problem types Identified 91 DC4000 Machine Dynamic Analysis software tests and features 91 DC4000 software navigation and overview 94 DC4000 software overview 91 160 Dynamic Motor Analyzer EXP4000 User Manual DC connections for the EXP4000 portable sensors 92 DC machine Field Resistance troubleshooting 118 DC machine la ripple troubleshooting 114 DC machine la troubleshooting 117 DC machine If troubleshooting 120 DC machine low field resist
50. RPOSE 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 si
51. T 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 gt All Programs gt Ex
52. a Eeer 8 ESE CO aN DURON eena E E AE 10 Results panels anid WINdOWS sucssisssesrusiuiisuissdisiredr iain cansanscectnespasticaaeavescanaeaataatatendeeseees s 10 E A E A A N EE A A A ENTE 12 Keyboard SNOT tOUS cere cscvecesciscxsatcsarasesiacnecanewieenevaenvenasnneeoncoesstadi sae eereueesn eens oteos 13 OO E E E A A EE AN 13 4 Connecting the EXP4000 15 Physical setup of EXP4000 with portable SeNSOTS eee ceecsscesscescssssessecssesesesesens 15 EXP4000 connections to motor terminals cceeecsscssessessesscssesessescescesesscsscecseeseeseeas 16 Connection SeU WINAOW seme meet ete aE eet pny Or ne Oo EE a Se ne ee 16 Manual phasor adjUstMentS cccccceccecccssccsccssccssccssccsccsssssscssscssssssssssssssesscsescssessseesens 18 5 EXP4000 tests 19 Test COU SS I MEO Yossie ienei ane EE Ei T9 Power Quality domai asses ieanicasc tate este astssse cond nN E EE EEEE 20 REULL IN E AOE ETE A E EEE ETEA EO A E ET 25 Table of Contents MACHINIST Ol aCe domal ierse Ei 26 ETE COU A 1E seers E ANA A A A EE E E E O EET 31 OPO CCF el E IEA 1 CAE E E A E E A AE A AE AEE 33 MOTT O a EN 37 Comecon dona Mieres ian E E E EES 40 6 EXP4000 software overview 43 EUERE E a T E E E A A E E wee eee A ATESA A A 43 A R O ee E EEEE pasate ens aeenesecaeseegacee 45 PAG UNV T NU eea AAN E TEE E E EE 46 e aa e 1 MN a E E E A E E E A 51 TO E E E E AE 54 FUE ME eaae E E E a 64 7 VFD4000 analysis software option 65 Operon de aS en EE E TEER 65 EE E A E oe oc A E
53. ameters and database features general database and archive General tab Use the General Options tab to set several system parameters The Calculator Path field and Browse button are use to identify the path to system s calculator The currency type can be set from here The default is USD US dollars Type in the currency name then use the dropdown list to select the symbol that represents the currency chosen Figure 117 User Options general options Use the Unit dropdown list to select either US or Metric Screen colors can be changed by clicking on any of the color schemes listed in the Display Style dropdown aKF Dynamic Motor Analyzer EXP4000 User Manual 103 DC4000 software overview When you are satisfied with your changes click Apply and then OK Database tab Use the Database tab to set the location for the database files along with the type of database is to be used as the default For database types you can select from Access Database mdb Sql Express Database mdf or Sql CE Database bic User Options Default Directory By default all databases will be looked for and placed at this location C Program Data Baker Instrument Data Default Type The default type of database to create Access Database mdbx Figure 118 User options database Archive tab Use the Archive tab to set the location of where archives will be stored This is an important feature to rem
54. ance troubleshooting 119 DC Machine Va form factor troubleshooting 113 DC machine Va troubleshooting 110 DC machine VF troubleshooting 111 DC sensor voltage ratings 92 Default settings 137 Defining channel for the graph or scale 76 Delete Test Model 53 Deleting a test model 101 Demodulated Spectrum 35 Display tab 62 Drive domain 109 Dynamic Testing tab 49 E Editing a test model 101 Edit Test Model 53 Effective Service Factor 26 Efficiency 28 Electrical connections 149 Environment conditions storage 6 EP 56 aKF Index EP4000 installation 145 EP4000 ratings 150 EP Caching 58 EP Calibration 64 EP Calibration Wizard 58 Event Triggers 72 Example test and report generation 131 Exit 45 Exit button 107 EXP4000 connections to motor terminals 16 EXP4000 software overview 43 EXP4000 software specific features 7 EXP4000 tests 19 F Field Current Level 120 Field Spectrum 125 Field voltage level Vf 110 File menu 43 70 formatting 1 Frequently Asked Questions 140 G General operation icons 73 General safety precautions 3 Glossary of terms 152 Graph Plot Mode 72 Grey shaded fields 7 H Hardware installation 147 Harmonic Distortion 22 Harmonics 25 36 128 Help menu 64 High Field Resistance 118 l information devices 1 Installation requirements 6 Installation safety warnings 146 K Keyboard shortcuts 13 L Load 27 121 Load level 123 Looking at data collected 132 Loop acq
55. any loss or damage whether direct indirect or consequential arising out of the use of the information contained herein UB 71 131 V2 EN Surveyor DX User Manual April 2013
56. are 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 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 Avg RMS A Average of the root mean square values of the three phases currents in amperes V Avg RMS V Average of the root mean square values of the three phases voltages Imbal Current imbalance percentage For machines under load this value is typically smaller than one eighth of the voltage unbalance percentage Voltage imbalance percentage Angle between the current phasor of phase A with respect to the voltage phasor of phase A which is locked at O degrees This number is equal to Za angle V Imbal IA Angle deg IB Angle deg Angle between the current phasor of phase B with respect to
57. 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 Meaning of button color code 108 Green Machine running within tolerances No action needed Yellow Machine has exceeded a caution threshold Action should be taken to avoid future problems Red Machine has exceeded a warning threshold Action needs to be taken to correct problem Blue No applicable thresholds Dynamic Motor Analyzer EXP4000 User Manual aKE DC4000 software overview Drive domain The Drive domain observes the upstream power Poor power condition will expose the motor to unnecessary stress 1 Click the Drive button to view the domain tests 2 Click on any test to view the results or test logs Armature voltage level Va Function Armature voltage level is the main variable to control speed It is always created by the drive speed varies proportionally to Va 1 To change speed change Va 2 Toreverse direction of rotation reverse Va k Fa Jax Ra Speed yi if and Poe er ER Aid i Speed 7 D imi Fi Aree Wool cape Deel Figure 127 Armature Voltage Level Typical threshold Nominal Va_Nameplate lt Va lt Va_Nameplate Warning threshold 120 Va_Nameplate Caution threshold 110 Va_Nameplate
58. 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 View menu item Volts currents Voltages Currents Power factor Power Apparent power Reactive power Z angles Machine New view ae Continous Monitoring File Machine Tools View Options Help Voltages Currents Power Factor Power Apparent Power Reactive Power Angles Machine New Figure 70 View menu Description 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 Displays the root mean square of the voltage for phase A B and C in volts 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 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 This displays the single phase real power for phase A B and C and the total power in kilowatts Displays single phase complex power 9 kVA values for phases A B and Cin kilovolt amperes Displays single phase com
59. ay oae TETO TE 11 Figure 141 Armature Spectra 126 Dynamic Motor Analyzer EXP4000 User Manual aKE DC4000 software overview Torque spectrum The torque spectrum is composed of both electrical and mechanical components The electrical component can be reduced by addressing issues pertaining to the armature voltage form factor and armature current ripple voltage unbalance unsymmetrical firing of SCRs and insufficient drive pulses Some applications for example such as extruders require very little torque ripple In these applications it is critical that the ripple be addressed When the electrical components of the torque spectrum have been Isolated whatever is left is a mechanical signature Amai Speta e um nim DAI TEE Figure 142 Torque Spectra aKF Dynamic Motor Analyzer EXP4000 User Manual 127 DC4000 software overview Harmonics Harmonics provide an indication of how much alternating current is feeding the DC current motor When a DC 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 and so on 1 Click on the Harmonics domain button to view the harmonics involved with the machin
60. 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 33 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 Enable te dala WEA Eaperl ip raih d ELN wie tr wie yr Fep FR ft 0 TG hi pa CFA AY on 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 ca
61. 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 File Options Apply the following Triggers ee So e WANS TAN oere gt Vaue 000 Ceres vate gt 00007 fn crus Gamiarvene v 000 emee evee fr oo 1 1 Oams Osea o0 Denseca 00 1 E verusm emas vaue 000 masce x 00m a ot TES r a otc OH A TE 1 Avg RMS A rarayan ooo emanean oo 1 o W Ana RMS Mi Crema gt vave _ gt 0000 emas vae e F l 1 SP c cn IE IC Arte doo Cremna vane z ooo formae evne fe om 1 1 EEEN Ceran zva z 000 emae vae 0000 Figure 72 Event Triggers window 72 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 b
62. buttons provide access to specific test results and indicate the status of test results e 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 e The Display phasor icon open a new window showing the Phasor diagram for the related machine e 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 Unbal current unbalance percentage e 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 e Sensor portable internal or EP external e CTs current rating of the CTs e Auto Phase
63. 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 Spectra ZoomInfo Graph Options CLERA l I I 1000 1500 2000 Frequency Hz AX 0 000 Hz 0 0 CPM AY 0 000 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 F
64. cause e Va Form Factor is too high e Drive malfunction e Timing of SCR s is wrong e High AC voltage unbalance e Armature circuit s inductance too small 114 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview Possible effects e The drive s supply introduces excessive variations in the motor s armature current This creates excessive torque ripple for applications defined as essentially torque ripple free Some applications for example extruders function properly only if the supplied torque Is sufficiently constant e AC current components contribute more to heating than to torque generation aging the armatures prematurely Additionally AC armature current components diminish the commutation capacity aKF Dynamic Motor Analyzer EXP4000 User Manual 115 DC4000 software overview Machine domain The Machine domain displays the issues directly related to the motor s health A machine can be a motor or a generator Figure 131 Machine domain tests 1 Click on the Machine domain button 2 Click on any of the machine domain tests to view the test results or logs available 116 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview Armature Current Level Function The armature current la level represents the current flowing through the armature winding Figure 132 Armature Current Level Typical thresholds Warning threshold 120 rated lt
65. 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 25 EXP4000 tests Machine Performance domain Effective Service Factor e 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 Machine Performance Effective Service Factor Results EF SF Load NEMA Derating Close Figure 15 Effective Service Factor within the Machine Performance domain 26 Dynamic Motor Analyzer EXP4000 User Manual aKE 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 fo
66. 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 53 EXP4000 software overview Tools menu The Tools menu has a number of items that will assist in monitoring machines Scope Fi Continuous Monitoring V2 View Connections F8 Transient Analysis Fa EP Run Electrical Looped Acquisition Vibration Operating Curves 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 e Phase to phase voltage e Phase to phase current Milliseconds Current Date Time 5 9 2013 3 21 03 PM Acquisition Date Time 5 9 2013 3 20 54 PM p Figure 45 Virtual Scope tool 54 Dynamic Motor Analyzer EXP4000 User Manual aKF EXP4000 software overview Items found in the Settings menu provide you with options for defining the scope s display properties Sox Settings Current Scale Mod
67. ctor Relative amount of operating current and voltage used to transmit power It Is defined as the division of real power by the multiplication of current and voltage Service Factor Specified on the nameplate displays the amount with which the rating of the motor may be multiplied for transient operation Test Domains The five testing regions within the EXP4000 Thresholds The point at which a stimulus is of sufficient intensity to produce an affect Torque Ripple Measure of time varying torque divided by steady state or average torque Total Harmonic Distortion Measure of harmonic content to a signal when compared to the amount of fundamental Triggering Method with which it is possible to start data acquisition when certain conditions of the signals are met 152 Dynamic Motor Analyzer EXP4000 User Manual aK VFD Variable Frequency Drive Vibration Model Defined as a group of mechanical thresholds Waveform Displays the shape of a signal with respect to time aKF Dynamic Motor Analyzer EXP4000 User Manual 153 154 Dynamic Motor Analyzer EXP4000 User Manual aKE Appendix F Technical specifications Table 6 General specifications CD RW EXP4000 is shipped with either an internal or external USB interface CD R W Computer OS Microsoft Windows XP Professional or equivalent Networking Compliant standards IEEE 802 11b and IEEE 802 11g Data link protocol Ethernet Fast Ethernet Gigabit Ethernet IEEE 802 1
68. ctra have to be the result of the voltage sources the field winding resistance or the field winding inductance A field circuit powered by rectified three phase AC should display harmonics at DC and multiples of the 6th harmonic 6th 12th 18th and so on No harmonics should be displayed at multiples of the second harmonic 2nd 4th 8th andso on 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 field current ripple the inductance of the field circuit could be too low This can be corrected by adding additional inductance externally to the drive and or motor field circuits TETE E E alj zj 1S 367 a5 Figure 140 Field Spectra aKF Dynamic Motor Analyzer EXP4000 User Manual 125 DC4000 software overview Armature spectrum As with the field spectrum armature voltage Va and armature current la should have similar spectra at lower frequencies However as frequency increases impedance also increases the impedance is mostly inductive As a result the armature current spectrum should decrease in amplitude at higher frequencies If this is not the case it is due to the machine The armature spectra Is useful in identifying the following problems e Raised bar e Raised Mica e Chattering e Neutral plane problems orgue per Eri Co ES i EA S
69. d 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 Alist 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 TA RMS IB RMS A IC RMS 4 VA RMS V VB RMS V VC RMS vV I Avg RMS A V Avg RMS V I Imbal b V Imbal New Graph K IA Angle deg IB Angle deg IC Angle deg VB Angle deg VC Angle deg ZA Angle deg ZE Angle deg C Angle deg Z Angle Avg deg Power A kW Power B kW Power kW Total Power kW New Gauge Figure 74 New Gauge New Graph menu with sample items 74 Dynamic Motor Analyzer EXP4000 User Manual aKE Continuous Monitoring Software option Moving gauges and graphs 1 2 3 Hover the mouse cursor over the item you want to move and click on the right mouse button The menu shown below appears Click on Move A hand graphic appears over the object to move Drag the object to the new location and click the left mouse button to set the object Scale Channel Move Figure 75 Move menu item right mouse button click
70. 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 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 A B C Avg Sum kW 213 5 201 8 195 5 _ kVAr 208 3187 304 9 377 2 362 3 KEA KER ECS ECS ETA Ea EIH I 270 5 2714 4 THDV 33 37 29 33 THDI 33 32 39 35 Cfv 149 1 50 146 148 Cfi 1 52 149 151 1 51 Voltage Unbalance Current Unbalance Frequency Hz Close Figure 13 Power data displayed within the Power Quality domain 24 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 Harmonics Select Channels Va E la Vb E b Ve E lc V Avg E 1 Avg Show Hamonics From 2 Figure 14 Harmonics within the Power Quality domain 1 Select the voltage and current
71. dware e MCC cable e EP mounting hardware e Jemplate for EP enclosure mounting Tools Needed e Small flathead screwdriver e Pencil or felt tip pen e Phillips Screwdriver e Hand drill e Set of Drill bits e Greenlee 2 1 2 punch Materials Needed e Switchboard wire SIS 14 600 V e Wire lugs 14 16 AWG 8 e Splice sleeves 14 16 AWG e y wraps T amp B 7 e Wire 14 600 V color green Ground Connection e Control Cable 3 C 14 AWG 600 V EPR CPE e Tag Book ABC T amp B e Fuse Block PT 600 V 2 Amp Safety precautions for EP installation WARNING Because of the dangerous currents voltages and forces encountered safety precautions must be taken for all tests Follow all corporate guidelines and those included here Due to the wide diversity of machine applications no attempt is made here to list or review all specific manifold general safety precautions However this manual includes special safety precautions applicable to the use of the EXP4000 Installation safety warnings Baker Instrument Company an SKF Group Company recommends the following safety precautions e Comply with all your facility s safety practices at all times e Ensure physical setup does not interfere with your facility s current or intended operation Additionally these safety precautions must be followed otherwise dangerous shock hazards may exist e Use whatever safety equipment required by your organization inc
72. e Voltage Scale Mode Plots Grid Lines Active Plot Acquisition Time Acquisition Rate Auto Range A se Beo A Min Frequency Apply Calibration Ct Selection Current Date Time 4 22 2013 9 55 01 PM Acquisition Date Time 4 22 2013 9 55 00 PM 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 143 43 17 25 Check Connections Figure 47 View Connections window aKF Dynamic Motor Analyzer EXP4000 User Manual 55 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 Triggered Acquisition Tri
73. e EP Serial Number field Assigning an EP to a motor 1 From the Tools menu click on EP Mode then Auto Assign NO Select the motor in the Machine Tree UO Set the main panel Sensor field to EP Connect the EXP 4000 to the EP 1 A From the Machine menu click on Acquire EP Serial Number O A message dialog will pop up to let you know that the EP was successfully assigned aKF Dynamic Motor Analyzer EXP4000 User Manual 49 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 Machine Properties Name LOW EFFICIENCY Power Out kW Speed RPM Sensor Ratios 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 c
74. e 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 s Continous Monitoring edadat File Machine Tools View Options Help Figure 67 File menu Machine menu The Machine menu is interlinked with the EXP4000 software File Machine Tools View Options E Machine Tree k F2 Create Machine Ctrl M Edit Machine Ctrl E Acquire EP Serial Number Reset EP Serial Number 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 View Connections Figure 69 Tools menu 70 Dynamic Motor Analyzer EXP4000 User Manual aKF Continuous Monitoring Software option View menu Several preset views are
75. e 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 7 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 A Continous Monitoring File Machine Tools View Options Help View Connections Machine Tree start recording stop Scope Figure 73 CMS general operation Icons aKF Dynamic Motor Analyzer EXP4000 User Manual 73 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 an
76. e given number of tests at 10 second intervals automatically saving the results as each test completes Looped Acquistion Test s to Run 40 Figure 81 Looped Acquisition dialog box 80 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 Time Looped Acquistion _ Test s to Run 1 Every Figure 82 Time Looped Acquisition dialog box aKF Dynamic Motor Analyzer EXP4000 User Manual 81 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
77. e 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 13 Getting started 14 Dynamic Motor Analyzer EXP4000 User Manual aKE 4 Connecting the EXP4000 6d 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 V zur For all connection procedures to minimize risk of injury or death from electric shock make sure the motor tis turned off before opening panels or making connections NOTE ai 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 2 3 A Connect the marked voltage clip ons to the voltage port on the EXP4000 Connect the marked current clamp ons to the current signal port on the EXP4000 Turn on power to the laptop 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 sens
78. e under test 2 To view the harmonics in different formats click on the tabs at the top of the screen 3 Click on the check box to view all four channels or as few as needed for each channel field current If armature current la field voltage Vf armature voltage Va Percent of Fienidarwent ad PMPEP Vs Pa FSGS Figure 143 Harmonics 4 Click on Export to view the available data formats This allows data to be displayed in several formats copied to the clipboard exported to a file for email or sent directly to a printer Size definitions are also available The unit of measure Is pixels Expecting Hanami Figure 144 Export Harmonics 128 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview Result The presence of any other harmonic particularly the 2nd indicates a lack of symmetry except for the case of a single phase rectifier Unusually large harmonics represent e On armature voltage can indicate an unbalance on the rectified supply e Ablown SCR e On armature current can indicate a high contact resistance Reports 1 To generate a report select the test records desired 2 To select multiple test records simply use the Ctrl or Shift Keys as in any Windows format 3 Click the right mouse button and select Add to Report The report will be created and a popup box will appear to
79. ed 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 oe Cee Die Check Connections 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 16 Dynamic Motor Analyzer EXP4000 User Manual aKF Connecting the EXP4000 realistic solution you will be prompted about load level Aselection of a high load scenario 90 and higher or a low load scenario 20 and lower
80. ed in the graphic below Create a New Database Create a New Folder View Properties Motor Master Opfline Testing Tools fe fag Morana Date Open a Database Create a New De Machine Calculator Figure 107 Icons used to access DC4000 features To enable the Create a New Folder and Create a New Dc Machine icons and their related functions a folder must be highlighted After you click on an Icon the related features work essentially the same as using the main menu access with the exception of the Create a New Dc Machine icon Explorer DC File Online Testing Tools Help ah mare create New Dc Machine j i Oe es e Click on folder saat Tim to highlight Icon enabled Click on icon New folder is created below highlighted folder directory Enter machine name then press enter on keyboard Figure 108 Create New Dc Machine icon in toolbar When you click on this icon rather than starting the Create Jest Item wizard a new folder is added below the highlighted folder when the icon is clicked Enter a name for the folder machine then press Enter on your keyboard The Create Machine dialog appears for you to complete the nameplate information as described earlier 98 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview Viewing properties Clicking on the View Properties icon opens a window like the one shown below For Database and Folder levels the window shows only the Location
81. ees 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 aKF 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
82. ember if you ever need to locate an archive Also the EXP4000 creates a large amount of data points These data points can create large databases of many mega bytes Using this tab you can define the Max Archive Size so that the data can be sent to different devices without issue If the database is larger than the archive max size the software will break the file size into appropriate pieces and archive all of the data By default all archives will be looked for and placed at this location C Program Data Baker Instrument Archives Open Folder Location Max Archive Size When Creating archives they are split at the size specified here 12 Gey Figure 119 Options menu archive 104 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview Software testing screen The following description of the DC4000 software will aid in understanding how data Is gathered Figure 120 DC4000 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 2 CT Selection 10 100 60 600 Field 1004 Armature A Figure 121 CT selection Nameplate Information The information listed in the top portion of the screen Is from the nameplate information that was entered when the machine was created Th
83. en as potential energy waste in the power bill and it degrades motor health 28 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 zZ NOTE To ensure the accuracy of the efficiency estimation the correct stator resistance must be
84. en completed click on the Check Connections icon located on the main screen of the software of the main window Run Hectrical Check Connections icon located in lower right quadrant A Run Vibration ia Figure 147 Check Connections icon 5 If the connections are not correct and the machine is not a VFD machine the autophasing will automatically correct the connections 6 If the machine is a VFD machine autophasing is automatically turned off The connections must be manually corrected 7 Click Run Electrical This will run all preprogrammed settings for the machine connected 8 When testing is done scan the front panel results for accuracy If all is fine write the testing to the database Example test and report generation Looking at data collected It is important to look at the data gathered prior to writing it to the database If the data Is deemed Inadequate or mistaken it can lead to misinterpretation of results Parameters can be adjusted and the testing redone if the front panel results are not reasonable for the machine Adjusting parameters If the torque speed curve has a red dot appearing in the graph area it can be from a speed miscalculation rotor bar problems an incoming voltage problem or another cause Check the speed in the nameplate Terque Speed 3420 0 3500 0 3550 0 3600 0 RPM Figure 148 Torque speed parameter adjustment If the current draw is incorrect check the CT select
85. entered for the motor when the new AC machine Is created Efficiency Load 108 1 Calc Losses k Efficiency Target Losses kW Figure 18 Efficiency test within the Machine Performance domain aKF Dynamic Motor Analyzer EXP4000 User Manual 29 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 Payback Penod Measurement 4 Efficiency Difference 4 Load 7 List Price Note Figure 19 Payback period within the Machine Performance domain 30 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 phase
86. 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 N
87. es 99 Viewing results 82 Viewing Spectrum results 83 Viewing Time Waveform results 82 Viewing Trending results 8 7 View menu 71 View menu item descriptions 1 V I Spectrum 34 Voltage connections 149 Voltage Level 20 Voltage sensor connections 93 Voltage Unbalance 21 W Waveforms 40 66 124 aKF Dynamic Motor Analyzer EXP4000 User Manual 163 Index 164 Dynamic Motor Analyzer EXP4000 User Manual aKF The Power of Knowledge Engineering Drawing on five areas of competence and application specific expertise amassed over more than 100 years SKF brings innovative solutions to OEMs and production facilities in every major industry world wide These five competence areas include bearings and units seals lubrication systems mechatronics combining mechanics and electronics into intelligent systems and a wide range of services from 3 D computer modelling to advanced condition monitoring and reliability and asset management systems A global presence provides SKF customers uniform quality standards and worldwide product availability SKF is a registered trademark of the Baker Instrument Company an SKF Group Company SKF Group 2013 The contents of this publication are the copyright of the publisher and may not be reproduced even extracts unless prior written permission is granted Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for
88. es the program aKF Dynamic Motor Analyzer EXP4000 User Manual 45 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 Machine Thresholds Tools He New Ac Machine h F3 Machine Properties F Acquire 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
89. ests 1 To access the looped acquisition mode click on the Online Testing menu then Looped Acquisition 2 Highlight and type in the appropriate number of tests or use the up and down arrows to select the desired number 3 Click Start after set up is complete Looped Acquistion _ Number of Test to Perform 10 Complete 0 Remaining Laa Figure 114 Looped acquisition Timed mode allows you to specify a number of continuous looped acquisitions to be repeated in intervals between tests that are user specific Figure 115 Time Looped Acquisition You can chose the start time to either be immediate or at a specific time and date Ending the testing can be similarly chosen 102 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview Tools menu There are two choices in the Tools menu The Motor Master tool gives you a research tool for motor efficiencies and workability It helps you find motors of like size capabilities and efficiencies It will also allow you to research motor details to see if it is working within prescribed tolerances Explorer DC File Online Testing D g Options Figure 116 Tools menu Motor Master option This option is available for download from the U S Department of Energy and is not installed at the factory Options The Online Testing menu Options item provides access to three options that allow customization of several system par
90. ge and current ratios as needed then click on OK Sensor Ratios Voltage Ratio to 1 Current Ratio 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 Machine Properties Manufacturer NEMA Design Model Enclosure Locked Rotor A 0 0 Frame Insulation Service Factor Seral Number 1 00 Figure 38 Machine Information tab 48 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 Machine Properties Name NEW AC Machine Byna fosg Stator Res L L 0 Hours per day EF Serial Number Figure 39 Dynamic Testing tab When an EP has been assigned to a motor the serial number of the EP will appear in th
91. gger Source Voltage Level Curent 11 60 A Acq Time sec CT Selection Pre Trigger Time sec 1 Auto Phasing does not work in Startup Transients Cancel 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 Manual Acquisition Acq Time sec CT Selection DA Auto Phasing does not work in Startup Transients Figure 49 Manual acquisition dialog box 56 Dynamic Motor Analyzer EXP4000 User Manual aKE EXP4000 software overview e Ena LEIT m n at L i amp i il Aaj P Sm u eee babe El b poeagd a d EF atten Teme PE rea 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 torques 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
92. gned 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 CMC Fort 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 agr
93. he 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 e EXP4000 e Power cord e CTs e PIs e Cabling e 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 e Corrugated cardboard package containers double walled with a minimum burst test of 275 pounds per square inch and e Two to three inches of shock absorbent material surrounding the entire unit z NOTE Cardboard newspapers and similar materials are not considered good shock absorbers 6 Dynamic Motor Analyzer EXP4000 User Manual aKE 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
94. hes e The number of pulses generated by the drive is too low aKF Dynamic Motor Analyzer EXP4000 User Manual 113 DC4000 software overview Possible effects The drive s supply introduces excessive variations in the motor s armature current This creates excessive torque ripple for applications defined as essentially torque ripple free Some applications for example extruders function properly only if the supplied torque is sufficiently constant An excessive armature voltage form factor can cause excessive armature current ripple resulting in additional commutator sparking Armature Current Ripple Function This is current that produces no torque yet produces heat Primarily armature current 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 to 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 Figure 130 Armature Current Ripple Typical thresholds Joa ain Ia Ripple Factor fay Warning threshold 2 5 lt la ripple factor Caution threshold 6 0 lt la ripple factor lt 2 5 Standards NEMA MG 1 Section 1 14 61 DC machine la ripple troubleshooting Result Armature current ripple is too high Possible root
95. ide strain relief for all current and voltage wiring as well as the DB25 cabling at the EP enclosure Verification of installation 1 2 Energize cabinet Connect umbilical cable between Explorer and EP panel plug w W Set Sensors switch to EP position Open the Explorer software and create a new motor ID Press Run Electrical button aKF Dynamic Motor Analyzer EXP4000 User Manual 149 EP4000 ratings e Voltage Terminal 1 000 VAC CAT Ill e Current Terminal Use Specified Current Transformers e A D Bus Connector Use Specified Umbilical Cable e Input 5VDC105 mA e Connect Only to EXP4000 or Similar 150 Dynamic Motor Analyzer EXP4000 User Manual ok Appendix E References and glossary Standards 6 NEMA Std MG 1 2003 Motors and Generators Literature 1 Mohan Underland Robbins Power Electronics Wiley amp Sons 1989 second edition ISBN 0 471 58408 8 2 El Hawary Electrical Power Systems Reston Publishing Company 1983 ISBN 0 8359 1627 4 3 Gross Power System Analysis John Wiley amp Sons 1979 ISBN 0 471 01899 6 4 Stevenson Elements of Power System Analysis 1982 fourth edition ISBN 0 07 061278 1 5 Fink Beaty Standard Handbook for Electrical Engineers McGraw Hill 2000 fourteenth edition ISBN 0 07 022005 0 6 Dorf The Electrical Engineering Handbook CRC Press 1993 ISBN 0 8493 0185 8 7 Fitzgerald Kingsley Electrical Machinery The Dynamics
96. ion from the front panel or the connections button The physical connection might not be right or there could be a bad connection Override speed If the speed is wrong it can be overridden Click on the Tools menu then select the Speed Override item Enter the appropriate speed in the field and ensure the On box is checked Speed Override Figure 149 Override speed 132 Dynamic Motor Analyzer EXP4000 User Manual aKE Example test and report generation Adjusting electrical acquisition time This will affect absolute test time and increase rotor bar test resolution If rotor bar problems are suspected it can be helpful to increase the acquisition time to obtain more data Hamionics to Save Min Frequency Hz Max Frequency Hz Spectrum Acquisition Options Acq Time sec F Max Hz Figure 150 Electrical Acquisition options Spectrum Acquisition options This adjustment allows you to change the frequency range being monitored along with the resolution This affects the voltage current and the torque spectrums Electrical Acquisition Options Acq Time sec Harmonics to Save Me Fncy Fe Max Frequency Hz 150 Figure 151 Spectrum Acquisition options aKF Dynamic Motor Analyzer EXP4000 User Manual 133 Example test and report generation Looped Acquisition Timed Acquisition In the Tools menu there are two types of loop acquisition modes continuous and time looped In continuous looped ac
97. ion of the cabinet for example doors opening terminal blocks covered slide rack interference 5 The physical location of the EP does not cause an electrical environmental or safety hazard 6 An Earth ground from the motor cabinet to the EP ground stud is installed The EP may be affixed to the interior of the cabinet by any means deemed appropriate however it is recommended that a positive mounting system such as metal screws be utilized Supplied with the EP is a mounting template for the enclosure as well as self tapping metal screws The template is a 1 1 representation of the EP enclosure and can be used for location assessment as well as mounting hole placement Once the location Is decided 1 Mark the mounting holes from the template to the cabinet 2 Remove the template 3 Drill the mounting pilot holes 4 The EP enclosure may now be mounted to the cabinet with the screws provided aKF Dynamic Motor Analyzer EXP4000 User Manual 147 Choosing a suitable location for the panel plug The panel plug is to be mounted on the door of the cabinet The location should be easily accessible from the outside of the cabinet providing the user an easy and obvious hookup scheme Once the location is decided 1 Mark the center hole to the cabinet 2 Drill the center hole 3 Using whatever means deemed appropriate remove the center cutout It is recommended a 2 4 Greenlee style punch be used to create the cutout 4 O
98. ircuit Field Figure 98 Portable field voltage connection greater than 500V aKF Dynamic Motor Analyzer EXP4000 User Manual 93 DC4000 software overview DC4000 software navigation and overview Navigating the DC4000 software Is accomplished via the main menu bar the icon toolbar and the Navigation Pane Fie Gasite Teoh Help _ Cet B oe es Main mera bar Lo leon toolbar iS CLASS PR AE e Pre DC Faachoee 2 Piper Di ache 3 Havigaton Pane can be pinned to left edge of window to create more viewing space Figure 99 DC4000 navigation tools and options File menu The File menu Is used to initiate database and folder management functions Open Database Close Database New Folder Ctrl F New Test Item Ctrl M Exit Figure 100 File menu 94 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview Creating a new database 1 Click File then New Database The Create New Database dialog box appears as shown below 2 Type a name for the new database that is relative to the operation then click OK This database will now appear in the tree view on the navigation pane on the screen 3 There are three types of database structures choose the database structure appropriate to the application Type of Database to Create Access Database mdbx Database Name Figure 101 Create new database dialog box Opening a database 1 To open
99. is information is for reference for what was originally entered for the machine a n erem T a bm ims wl eo wf xo x tw an 0 i cw n bass Figure 122 Nameplate Information aKF Dynamic Motor Analyzer EXP4000 User Manual 105 N DC4000 software overview Center of screen VAX VF 3 LA 3 5 i t 100 a Ve oy ANa Ain a AN 331 5 V RAB fi 25 57 bA Torque Figure 123 Center of screen Parameters Fi o4 Percentage of Synchronou Speed VA Armature voltage percentage e VF Field voltage percentage e A Armature current percentage e F Field current percentage e Torque ft lb Torque in foot pounds torque N m Torque in Newton meters e Load HP Load in horse power load kW load in kilowatts e Load Percentage load e Va If Percentage of synchronous speed equivalent Waveforms can be zoomed in on to display cycles e Zoom in Shift and hold left click button then drag box around area of interest e Zoom out Ctrl and right click button will return screen to original zoom level Practical data resulting from the waveforms e Firing sequence e Fining angles determined by amplitude of waveform e Broken SCR extreme firing angle e nput voltage unbalance Phases may be off lack of symmetry in waveforms e 3 phase 3 3 SCR switching symmetrical waveforms unless too much ripple is present e Typical DC drives will not have a flat
100. istance too much from the drive s motor model could introduce stability problems to speed or torque control e f the motor s nameplate does not properly represent the field circuitry the field s resistance varies too much from the drive s motor model which can introduce stability problems to speed or torque control 112 Dynamic Motor Analyzer EXP4000 User Manual aKE DC4000 software overview Armature voltage form factor Function Form Factor Is defined as Fa aure Fa Form Factor A average Arm Cerner Fesat Tea Log Measurement Thresholds la Ripple iiH i Anm Yond age Pen a lS Figure 129 Armature Voltage Form Factor This is a representation of how much armature voltage Va differs from a pure DC signal The closer the armature voltage form factor is to 1 0 the theoretical minimum the cleaner the signal An armature voltage form factor greater than 1 0 indicates AC current components in the armature and could mean more losses Typical thresholds The following boundaries apply to DC motors operating from a rectified AC supply Warning thresholds 120 Va_Rated 80 Va_Rated Caution thresholds 110 Va_Rated 90 Va_Rated Standard NEMA MG 1 Section 1 12 64 DC Machine Va form factor troubleshooting Result Va form factor Is too high Possible problem root cause e Excessive voltage unbalance feeding the drive e Unsymmetrical firing of the drive s armature circuit switc
101. ively 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 Manual Ctrl M About Ctrl A Release Notes EP Calibration Motor Master Figure 63 Help menu 64 Dynamic Motor Analyzer EXP4000 User Manual aKE 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 Inthe Machine Properties window Name Plate tab check the VFD box VFD mode The EXP4000 has two
102. l 1 Click on the Online Testing menu then Edit Test Model The Select Test Model dialog box opens as shown below 2 Use the Select Test Model to Edit dropdown list to locate and select the test model you want to edit 3 Revise the threshold levels as needed then click on the Apply button 4 Make other changes as needed and click Apply 5 Click on the Close button when you are ready to save the changes to the test model leave the dialog box and return to the main window NOTE The default test model cannot be edited or deleted Select Test Model Select Test Model to Edit Defaut Hec De kai Test Model Name Defaut Hec De Figure 112 Edit test model Deleting a test model 1 Click on the Online Testing menu then Delete Test Model A dialog box appears like the one shown below 2 Use the Select Test Model to delete dropdown list to locate and select a test model 3 Click on Delete A confirmation box will appear Double check that this action is appropriate then click on the appropriate response Delete Test Model Select Test Model to delete ee a Defaut Hec Dc ated Figure 113 Delete test model aKF Dynamic Motor Analyzer EXP4000 User Manual 101 DC4000 software overview Using looped acquisition The equipment can be set to continually run in a looped mode for a specified number of t
103. la Caution threshold 110 rated lt la lt 120 rated DC machine Ia troubleshooting Possible problem 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 117 aKF Dynamic Motor Analyzer EXP4000 User Manual DC4000 software overview High Field Resistance Function The calculated field resistance is compared to field resistance at rated conditions extrapolated to the upper boundary of the insulation class biegh Peed ech ee Reni tewiLog Measurement Thresholds Field Res Hot ng Figure 133 High Field Resistance Typical thresholds R V jrated 4s rn r Ir Warning thresholds 120 RfHot lt Rf Caution thresholds 110 RfHot Rf 120 RfHot Result Field resistance is too high DC machine Field Resistance troubleshooting Possible problem root cause e High temperature e High contact resistance e Gauge of copper wire used for winding Is too small Possible effects e Shortened insulation life 118 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview 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 So Fiki Tet Log Measurement Thresholds Field Res Cold ix
104. lem root cause e High temperature e High contact resistance e Long leads of small diameter copper Possible effects e Over speed e Stalling 120 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview 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 ol x Figure 136 Load domain tests Torque ripple Imaged data short term behavior as well as load signature Load level history long term behavior is made viewable 1 Click on the Load domain to view tests 2 Click one either of the domain tests buttons to view the test results or logs available aKF Dynamic Motor Analyzer EXP4000 User Manual 121 DC4000 software overview Torque ripple Torque ripple is defined as the division of maximal torque divided by average torque during the acquisition period Figure 137 Torque ripple Function Torque ripple is a measure of how small the torque band is that surrounds a steady state average torque An important feature of the 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 ks laxIf Boundaries N A blue results Results Torque ripple is too high A torque ripple in a ripple free application indicates a problem Possible problem roo
105. luding eye protection high voltage gloves arc flash rated masks hoods and any required PPC Prior to opening any MCC Motor Control Cabinet ensure that appropriate arc flash protection clothing is worn e Ensure that appropriate lockout tag out procedures are properly understood and implemented by all personnel e Ensure motor s phase connections are not positioned near ground or near each other 146 Dynamic Motor Analyzer EXP4000 User Manual aKE N Hardware installation NOTE It is necessary that each EP is provided 3 phase voltage not in excess of 1 000 V AC and a good ground Some switchgear installations will require this voltage to be wired from the bus cabinet to each cabinet being outfitted with an EP For motors rated at voltages higher than 1 000 V AC secondary output voltage from the PT s are acceptable as long as all three phases are present as line to line voltages and are lower than 1 000 VAC Choosing a suitable location for the EP The EP may be mounted in a variety of locations as long as the following criteria are met 1 The EP must be installed in a cabinet or enclosure that is secured with a tool or key lock 2 Voltage and Current lines can be easily and safely ran to the EP in accordance with applicable electrical codes 3 The connector cable can reach the cabinet door and the movement of the door is not restricted 4 The EP does not interfere with or complicate the mechanical operat
106. mage aKF Dynamic Motor Analyzer EXP4000 User Manual 111 DC4000 software overview e Series poles connected in series have been removed from the circuit Possible problem root cause Case II If gt If_field_weakening e Field circuit s resistance is lower than nameplate suggests e Field winding s temperature is below standard ambient 40 C or motor may not have warmed up yet e Series elements of the field winding are not part of the circuit turn turn faults e Nameplate vs motor issue e Error entering the nameplate when creating the motor e Motor s nameplate does not properly represent the field circuit e f the field circuit s resistance is lower than the nameplate suggests Possible effects If the field winding has a turn turn fault and if the field voltage has noticeable harmonic components the shorted turns are being overheated The field s ground wall insulation will fail prematurely The amount of overheating due to the harmonic current content 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 long enough time then the field winding Is still in the process of heating up If the drive does not change the Vf then It 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 Varying the field windings res
107. main sections The Measurement display indicates the severity of the test results compared to the threshold indicators 10 Dynamic Motor Analyzer EXP4000 User Manual in KF 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 e Red warning e Yellow caution e Green good e 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 E iB Ti a oa Voltage Level X Time 7 51 57 PM 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 11 Getting started Machine tree The left panel in the main user interface window is the Machine tree
108. merly 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 NON INFRINGEMENT ARE HEREBY DISCLAIMED AND EXCLUDED BY SKF CMC FORT COLLINS FORMERLY BAKER INSTRUMENT COMPANY 6 Limitations on Liability a Limitations and Exclusions INNO 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 aKF 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 PU
109. 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 V and l sequence do not coincide 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 a NOTE Voltage Is connected in abc and current in acb sequence 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 th
110. n 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 gz 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 WARNING Indicates a hazardous situation with risk of serious bodily injury or death About this manual 2 Dynamic Motor Analyzer EXP4000 User Manual aKE 2 Safety and general operating information General safety precautions The general safety information presented here Is for operating and service personnel D 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 Caution Indicates a hazardous stuaton which if mot avoided could result in personnel ingury and or equipment damage Voltage level warming Located on labeling for test leads on side of msirument Ar Current Input Use specified current probes EP Vibration Input Use specified EP and Vibration cables Voltage Input AC 1000 V CAT III DC 500 W Figure 1 EXP 4000 safety label
111. n 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 34 Dynamic Motor Analyzer EXP4000 User Manual aKE 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 a Band scale Bare projection CTT TTT TN 2 amp EEFE l range Fraquarmcy Hz al fest fo sop Fel Frequency oO bb ok kl lll aj of apecinum Tepa HU sete FS tree m T NE a SN Channei selector e Viewsng conircls 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
112. nce the cutout is removed place the plug over the hole and mark the four mounting holes 5 Remove the plug and drill the four outer mounting holes 6 Mount the plug and the backplate using the supplied hardware 7 Provide strain relief for the cabling attached to the panel plug Current transformer CT connections 1 Verify that all three CTs are marked with the same bin number this is a number between 1 and 5 2 The supplied CT donuts are to be placed on the three voltage feeds to the motor 3 These should be placed on the load side of any line protection devices circuit breakers Care should be taken to ensure the dots on the CTs point toward the load motor Red is phase A blue is phase B and yellow is phase C 4 The Baker CTs should be installed on the output of existing CTs in the system for all motors operated at voltages above 1 000 V Check that the output of the secondary is less than or equal to the rating of the Baker CTs 5 Ensure there is enough wire length to connect to the EP If installed CTs are used be sure to note the ratio as this information will be needed when creating a motor ID 148 Dynamic Motor Analyzer EXP4000 User Manual aKE N Voltage connections NOTE lIOn motors with input voltages higher than 1 000 VAC it will be necessary to make the connection after a Power Transformer PT located between the voltage source and the EP Three phase voltage should be connected to the EP once
113. ncy bands for all currents and voltages Harmonics Select Channels Va Vb E ib Vc E lc V Avg E 1 Avg Show Hamonics From 2 Figure 25 Harmonics within the Spectrum domain 36 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 Torque Ripple E T o w 3 am g i D _ l l 6 8 10 026 Time s Rated Torque eee Torque Ripple Load Hi 5 F Figure 26 Torque Ripple window Results tab within the Torque domain aKF Dynamic Motor Analyzer EXP4000 User Manual 37 EXP4000 tests Torque Ripple Trend tab The Trend tab shows a graphical comparison of the torque results for the current and previous measurements ome te 32572 Figure 27 Torque Ripple window Trend tab within the Torque domain 38 Dynamic Motor Analyzer EXP4000 User Manual aKF EXP4000 tests Torque Spectrum Clicking on torque spectrum opens a window that shows the frequency spectra of torque The Y scale display units
114. ndition 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 e Power Quality Voltage Level Voltage Unbalance Harmonic Distortion Total Distortion Power Harmonics e Machine Performance Effective Service Factor Load Operating Condition Efficiency Payback Period e Current Over Current Current Unbalances e Spectrum Rotor bar V I Spectrum Harmonics e 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 e dentifies over and under voltage conditions e Compares measured voltage levels with user defined thresholds i Power Quality Voltage Level Voltage Level Ava A B B C A Val
115. ngs 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 aKF Vibration software option Viewing Trending results For the Trending tab clicking on the Plot Settings icon reveals three additional options Acceleration Velocity Displacement and Speed Not all options are available for every test conducted Those that are not available are grayed out Trending tab Plot Settings menu i items for Trending tab Figure 90 Trending display options Examples of Trending display options follow ey 4 25 201393012AM Gam A 9 ao Speed 1727 75 Acceleration 554 37 Velocity 1 51962 Displacement 0 00450 41390 554 37 N 8 o 5 300 3 5 41313 AY 554 37 l l l 01 01 01 11 29 00 A 01 01 01 11 29 40 A 01 01 01 11 29 50 A Figure 91 Trending Acceleration aKF Dynamic Motor Analyzer EXP4000 User Manual 87 Vibration software option lt i 4 26 20139 3012AM lt AE o Q Speed 1727 75 Acceleration 554 37 Velocity 1 51962 Displacement 0 00450 inches per sec i x oe MGHEER AY 1 28 41390 1 5196 l 1 l l 01 01 01 11 28 33 A 01 01 01 11 29 00 A 01 01 01 11 29 20 A 01 01 01 11 29 40 A 01 01 01 11 29 50 A Figure 92 Trending Velocity ahha WIDIGUOr i 4 26 201393012AM_ e A eo
116. ompleted 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 50 Dynamic Motor Analyzer EXP4000 User Manual aK 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 File Machine Thresholds Tools Help E MotAnal Select Test Model ra BASEME Create Test Model K B E CLASSIC ae M ns Edit Test Model ied E Delete Test Model 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 New Test Model 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 51 EXP4000 software overview Create Jest Model When you click
117. ord from the wall outlet and the unit before using e Do not coil power cord or test leads near motor leads e During repairs do not substitute any parts Use only factory supplied parts e his 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 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 Ill 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 AAC maximum current draw Environment conditions storage The unit is designed for indoor use If used outdoors t
118. orm Is smaller than the rest it is possible that one SCR on a six pulse rectifier is not firing properly Typically a DC drive does not utilize ripple capacitors so these waveforms typically are not flat In addition an entire missing tooth in the waveform could indicate a broken SCR Voltage unbalance should also be visible Because there Is more inductance in the field than in the armature field current should normally be relatively small high resistance with less ripple than armature current Figure 139 Waveforms 124 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview Spectrum Spectra are useful for analyzing the frequency content of time domain signals Armature voltage Va armature current la field current If field voltage Vf and torque are transformed to the frequency domain with the Digital Frequency Locked Loop DFLL and or the Fast Fourier Transform FFT 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 Field Spectrum Field voltage Vf and field current If should have similar spectra at lower frequencies As frequency increases impedance also increases the impedance is mostly inductive resulting in the field current spectrum beginning to decrease In amplitude at higher frequencies The field circuit does not interact with the load so any issues found in the field spe
119. ors 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 PIs 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 mix
120. ou can now perform tests again NOTE An existing machine with recorded tests cannot be edited In order to edit this machine you must delete all tests and then edit the machine How do I connect the EXP4000 to the secondaries of PTs if have an open delta configuration Open delta configurations are very common in the field for medium voltage or high voltage motors 1 Ensure that all safety precautions are being followed when working with live voltage Refer to the Safety Operating Information chapter for details 2 Identify the three different points in the MCC that show the same voltage typically 100 200 volts when connecting A B B C and C A One of these pins typically is the ground pin 3 Clip the ground connection to a viable ground in the MCC NOTE Typically this will be one of the three pins previously identified 4 Connect the three phase clip ons to each of the identified pins 140 Dynamic Motor Analyzer EXP4000 User Manual aKE How do I connect the EXP4000 s portable CTs if have only 2 CTs installed in my medium or high voltage motor The sum of currents concept applies in this situation 1 Connect the first two portable CTs to phases A and B 2 The third CT needs to be connected to both CTs around the other phases Make sure that the third CT totally closes around both currents of phases A and B If the CT doesn t totally close it will monitor much less current D NOTICE The third CT
121. plex power for phases A B and C along with the sum of the thee phases in kilovolt amperes 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 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 You can create a custom view to display the items necessary to your operation aKF Dynamic Motor Analyzer EXP4000 User Manual 71 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 fA Mk rt 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
122. plorer gt Explorer The Explorer main window appears as shown below Huir sekar MigePerah murr a Hrane ady pa 0 i 50 pay eii a Fe aa i His Saas Coming Fang Taie i ii fn i p P T ll mi demari cise at Ais cimi j mE J 1 j Ki YA ee i om 4 k H geese aie ha j Sas e Y Linked 5 a i A PA fe l Lined TA Perg Ha HFH E T f e Dipara 11 14 Lend Matera Fi ime Loved ae 1E Bpr Siain FIP maa TL ty 10 A A ETA ish ae er Torger mper dapiay Chai pitkih k 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 aKF N Getting started e 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 e The Machine information bar identifies the current motor or device under test along with the basic nameplate information for the machine e 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 e The Test domain
123. quisition mode a set amount of tests must be completed prior to the instrument stopping You should run a minimum of five tests but 10 is the optimal amount Looped Acquisition Number of Tests to Run 10 Run Until Manually Stopped OK Make this my default setting Figure 152 Continuous Looped Acquisition dialog box The second acquisition mode is time looped acquisition which uses a defined time and date as the trigger Time Looped Acquisition D 4 22 2013 10 38 05 PM Hectical Testis Figure 153 Time Looped Acquisition dialog box 134 Dynamic Motor Analyzer EXP4000 User Manual aKE Example test and report generation Creating reports from the report generator You can select multiple machines and results to generate a report but only machines with a stored result can generate a report 1 Click on the File menu then Report Generator to open the Select Results window shown below 2 Select the results to be included in the report by checking the box es next to the test result listed in the tree 3 Amachine summary page is automatically generated for each unique machine that is being included in the report Filter n Select Trending Qn gt H j easement S E j classic PROBLEMS 5 H i classic PROBLEMS S E BAD_ROTOR_BAR 9 CT_BAD_ROTORBAR E INCIPIENT_ROTOR_BA Fo LOW_EFFICIENCY Fi MILD_ROTOR_BAR fo OVER_CURRENT Fa OVER_CURRENT_ESF E ROTOR_BAR EP VeD_VOLTAGE_DIST FP
124. r e Reset from Zoom Press the Control key and Space bar simultaneously NOTE If a box appears when zooming In on X or Y axis only ensure that you are dragging the cursor straight with either the X or Y axis to get the horizontal or vertical guide lines aKF Dynamic Motor Analyzer EXP4000 User Manual 89 Vibration software option 90 Dynamic Motor Analyzer EXP4000 User Manual aKE 10 DC4000 software overview DC4000 Machine Dynamic Analysis software tests and features e Collect and graph field voltage e Collect and graph field current e Collect and graph armature voltage e Collect and graph armature current e Collect and graph transient data including start up transient e Calculate instantaneous torque and graph torque ripple and torque spectrum e Calculate harmonics on all voltage and current data e Calculate current spectrum e Calculate voltage spectrum e Cursors available to analyze torque and current spectrum data e Data can be exported for additional analysis with programs such as Matlab or Excel DC4000 Machine Dynamic Analysis software problem types Identified e Firing sequence and firing angle issues e Voltage unbalance issues e Voltage level issues e Analyze voltage form factor e Measure Incoming power condition e Failed SCR s or IGBT s e Diagnose brush fire e Diagnose brush chatter e Diagnose drive issues e Diagnose commutator problems e Analyze troubleshoot response of motor circuit e
125. r example you can add logos notations of tests network capable and more These annotations can be made in the report through normal text editor functionality Automatic generation of reports Results for tests conducted with the EXP4000 are automatically saved Reports can be generated from this data providing pass fail data numeric data and appropriate waveforms from tests Charts trend this data which Is logged with test dates Analysis of test results over time is a key tool in a predictive maintenance program 136 Dynamic Motor Analyzer EXP4000 User Manual aKF N Appendix A Default settings e Database Directory InstallDir dB e Archive Directory InstallDir Archives e EP Acquisition Find machine associated with EP and auto assign it e Elec Acquisition Options 10 Sec NOTE Two pole machines are always acquired with at least 30 seconds despite the Elec Acquisition options setting Default settings Table 3 Default settings yest ret Electrical Voltage Level Sy 5 al 5 Operating Condition bration oltage V a E ft units uscusomay o ceny fos o Votage mewes No Tests Show Tests with a Good rating Show Tests with a Caution rating Show Tests with a Warning rating Do NOT Filter test by Date 138 Dynamic Motor Analyzer EXP4000 User Manual aKE Appendix B Connection troubleshooting General The EXP4000 has two different modes of operation Non VFD 6
126. r allowing a higher load level prior to issuing an alarm Measurement 125 5 100 Curent Level Speed RPM NEMA Derating Factor Load F Figure 16 Load test within the Machine Performance domain aKF Dynamic Motor Analyzer EXP4000 User Manual 21 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 e achange in the operating process or e acondition 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 Threshold 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 l PISS n 100 1 Pin Where Ploss the power that dissipates mainly heat Pin input power Ploss can bee se
127. ree 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 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 Zoom netoling TT 510A Mla O lb Ole M Vab Figure 64 VFD waveform display 66 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 WFD Details Torque and Speed vs Time 1130 aa ee 1080 Torque ft lb ate H paads 1070 7 748 Frequency and Voltage vs Time 2
128. 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
129. req 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 39 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 Zoom Info Line to Neutral Line to Neutral Neutral Line to Line VV 300 r Li INT SIOA 5 ms Mia Hlb Ble M 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
130. rsonnel 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 22 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 Power Quality Total Distortion Total Distortion A B C Awa Figure 12 Total distortion within the Power Quality domain The commonalities and differences between THD and ID 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 23 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
131. s Safety and general operating Information Safety warnings 1 AWARNING 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 aKF Safety and general operating information Operational safety warnings Any operator of this unit
132. s 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 Current Current Level Measurement 120 100 A B C Avg Current Nominal Curent x Rated Figure 20 Current level test within the Current domain aKF Dynamic Motor Analyzer EXP4000 User Manual 31 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 Current Unbalance Current Unbalance A B C Avg _ Curent Unbalance Rated Al Figure 21 Current unbalances within the Current domain 32 Dynamic Motor Analyzer EXP4000 User Manual aKF 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 Rotor Bar 60 063 0 f Speed RPM 1801 0 Sideband Amplitude db Sideband Freq Hz Fund Freq Hz Figure 22 Rotor bar within the Spectrum domain The rotor
133. s option will print an overall summary of the testing done for the selected machine test in the Machine Tree 5 Machine Performance Report Time Date 12 12 2002 11 33 53 PM EXPLORER Database Mot Anal Test Model def aul elec Memo Location BASEMENT Test By Building ALAMO Test For Machine Serial No 200 HF 50 Manufacturer Po KW RPM W725 Volts Amps 210 Serv Fact 5 Stator Res L L 0 00E 0 Ohms Frame Insulation Speed RPM Mi Load Efficiency 4 1762 4 i ATT 46 4 Test Caution Level Wam Level Status Over Voltage Level x Good VUF PJ 05 20 35 God Harmonic Distortion VII 262 o a Good Total Distortion 4 Nominal Current 4 Eff Service Factor Rotor Bar Sideband db OpCond Losses KW Payback months 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 clos
134. save the report in a rtf rich text format which can be opened in a number of different software packages Electrical Results vaii 1 32212007 9 07 56 AM Jair SF Sh AM 3 22 2007 9 07 21 AM Add bo Report trf Delete Cred Figure 145 Right Click Menu Reports Report examples are shown on the next page aKF Dynamic Motor Analyzer EXP4000 User Manual 129 DC4000 software overview Explorer DC Electrical Resuli KMachiae Same Lecalics Tet DaeTie 1 H Aig Figure 146 Sample reports 130 Dynamic Motor Analyzer EXP4000 User Manual aKF 11 Example test and report generation This chapter provides general guidelines for using the EXP4000 dynamic motor monitor it does not cover all of the capabilities of the instrument NOTICE Ensure that all safety procedures have been read and understood before making any connections to or attempting to use the EXP4000 Refer to the Safety Operating Information chapter for details Motor monitoring 1 Prior to testing ensure that the software has been set up properly along with an appropriate database structure 2 Ensure that machines have been accurately input and that all thresholds for each test have been established Refer to the Basic Software Overview chapter for procedures and details 3 Connect the EXP4000 to the machine to be tested as described in Connecting the EXP4000 4 After hookup has be
135. t cause e Load problem e Drive problem 122 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview Load level The motor is required to deliver the load level requested by the load If there is a change in the load level the root cause of that change lies in the driven load not in the motor s capabilities Frade Test Log Figure 138 Load Level Function Load level displays the test history of the load Dynamic monitoring Identifies deterioration which in most cases is gradual making trending important 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 with detailed knowledge of the operating process Expertise in the particular driven load is necessary to determine whether the measured change is meaningful for predictive maintenance Typical thresholds Warning threshold 120 lt load Caution threshold 110 lt load lt 120 Possible problem root cause In case load level is too high e Load level problems are always caused by the load Possible effects e Overheating aKF Dynamic Motor Analyzer EXP4000 User Manual 123 DC4000 software overview Waveforms Waveform shape can be indicative of drive or motor problems For example if every sixth peak of the field voltage or armature voltage wavef
136. t 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 Graph Settings Seale Mode Auto Scale O Max Min Manual 0 00 Max 0 00 E Show Grid Lines m pa P 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 th
137. tab providing the name and the modified date and time At the machine level additional tabs provide information about the nameplate machine application manufacturer online testing and bearings Some items within these tabs can be edited Figure 109 Right click menu properties aKF Dynamic Motor Analyzer EXP4000 User Manual 99 DC4000 software overview Online testing menu Before testing can begin you need to provide the software with information needed to establish an understanding of what is being tested The Online Testing menu provides access to the tools needed to provide this information Timed Looped Acqustion Delete Test Model Acquire EP Serial Number Looped Acquistion Options Figure 110 Online testing menu Creating a DC test model 1 Click on the Online Testing menu then Create Dc Test Model The Create Test Model dialog box appears as shown below 2 Type a name for the new model in the Test Model Name field 3 Change threshold levels as needed by highlighting the threshold level and typing in the appropriate values Ensure that warning levels are higher than the caution levels Create Test Model a New Test Model Figure 111 Create new test model 100 Dynamic Motor Analyzer EXP4000 User Manual aKF N DC4000 software overview Editing a test mode
138. 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 ona 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 vil 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
139. top 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
140. ue Figure 9 Voltage level test within the Power Quality domain 20 Dynamic Motor Analyzer EXP4000 User Manual aKF EXP4000 tests Voltage Unbalance e Examines the single phase voltage in the motor by calculating its percentage unbalance via NEMA derating e Compares the voltage unbalance level with the stored threshold e 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 Power Quality Voltage Unbalance Bo CA Avg AB a Unbalance NEMA Derating 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 aKF Dynamic Motor Analyzer EXP4000 User Manual 21 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 Power Quality Harmonic Distortion V 4 Figure 11 Harmonic distortion Stator current torque and operating speed typically describe the health of a machine For example maintenance pe
141. uisition 59 Looped Acquisition Timed Acquisition 134 Low field resistance 119 M Machine domain 116 Machine information tab 48 Machine menu 46 70 Machine Performance domain 26 Machine Properties 50 Machine tree 12 Manual phasor adjustments 18 Meaning of button color code 108 Modifying the continuous monitoring tool 74 Motor monitoring 131 Moving gauges and graphs 75 N aKF Dynamic Motor Analyzer EXP4000 User Manual 161 Index Nameplate Information 105 Name Plate tab 47 Navigating the software interface New AC Machine 46 Numeric fields 8 0 Online testing menu 100 Opening a database 95 Operating condition OpCond 28 Operating Curves 60 Operational safety warnings 5 Operation details 65 Options 62 103 Options menu 72 Override speed 132 p Parameters 106 Payback Period 30 Phasors 41 Physical setup of EXP4000 with portable sensors I Physical setup of the EXP4000 with EPs 16 Plant maintenance Power 24 Power Quality domain 20 R Raw to CSV 61 References and glossary 151 Renaming a folder 96 162 Dynamic Motor Analyzer EXP4000 User Manual Report Generator 44 Reports 129 Reset EP Serial Number 50 Result 129 Results panels and windows 10 Result tab 10 Rotor Bar 33 Run Electrical 59 Run Electrical button 107 Running a looped acquisition scan 80 Running a time looped acquisition 81 S Safety and general operating information 3 Safety precautions for EP installation 1
142. waveform due to six pulse rectifiers or lack of ripple capacitors NOTE The field circuit does not interact with the load All load related signatures will make it into the armature but not the field 106 Dynamic Motor Analyzer EXP4000 User Manual aKF DC4000 software overview Bottom of main screen Run Electncal Figure 124 Bottom of main screen Run Electrical button Click on Run Electrical to run the programmed tests View Connections button Clicking on the View Connections button opens the View Connections window which provides you with a real time look at the input signals Armature voltage Va field voltage Vf armature current la and field current If are displayed in terms of average along with RMS min max peak to peak and percent of nameplate values The graph shows the waveform shape Load and torque are plotted versus time S375 a ai k a oe ee Figure 125 View Connections Exit button Clicking on the Exit button closes the software and returns you to your desktop aKF Dynamic Motor Analyzer EXP4000 User Manual 107 DC4000 software overview Test domains The right side of the screen has a set of test buttons known as domains Click on each individual button to see a subset of buttons and several test results screens Figure 126 Test Domains Drive Armature voltage level field voltage level armature voltage form factor

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