877-ETNCARE Press. Press. Press. Press. Press. Customer Segments. General Support. EatonCare Technical Resource Center

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1 877-ETNCARE General Support Customer Segments EatonCare Support: Component Order & Component Returns EatonCare Technical Resource Center EatonCare OEM EatonCare Project Order Support EatonCare Power Quality Amy 24/7 Automated Information System Price, Availability, & Order Status Order Expediting & Order Tracking Component Warranty & Returns (CORE) Distribution and Residential Products Power and Logic Control Panelboards and Switchboards Power Management Automation Products Drives Vehicle Controls Sensors and Limit Switches Commercial Support Technical and Warranty Support Commercial Support Technical and Warranty Support Building Information Modeling (BIM) Commercial Support Technical Support Field Services, Batteries, Part Replacements, Installed Product Support Power Quality Returns 1

2 EatonCare OEM Team Mission Maintain premier service levels that exceed our customers expectations and serve as a differentiator for our field sales engineers 2 2

3 Differentiation What to Remember Extension of Field Sales Team Customer & Process Knowledge Simplifying the Customer Experience Building Relationships Sophisticated Tools in Place Driving Customer Loyalty We Are Available 3 3

4 OEM Team 4 4

5 Documentation of Training your contact info to: Please let us know if you have any questions or requests, or if you would like a copy of the presentation. 5 5

6 C441 Motor Insight Energy Monitoring and Remote Diagnostics in Advanced Motor Protection Kevin Trimmer Product Manager Advanced Motor Protection 2011 Eaton Corporation. All rights reserved.

7 Agenda Introduction Fault Conditions Overview Overload Relays Overview Traditional (Bi-Metal) Solid-State C440 / XTOE C441 Motor Insight Online Monitoring Practices Overload Relays as a Complimentary Solution Monitoring Protection Diagnostics Energy Savings Case studies Summary 7 7

8 Fault Condition Overview Motor Protection Breaker/Fuses There are several fault characteristics in a system that can lead to early motor failure Understanding the source of each condition allows the user to reduce troubleshooting time Contactor Overload Relay Proper application of motor protection products allows for early indication and prevention of greater system failure Thermal Overload Jam Ground Fault Voltage Imbalance Current Imbalance Phase Loss Frequency Variance Phase Reversal 8 8

9 Fault Condition Overview Motor Protection Thermal Overload: Current draw to motor exceeds 115% of FLA rating of motor for given period of time Causes o Increased load/torque being driven by the motor o Low voltage supply to the motor o Poor power factor Results o Increased current leads to heat which can cause insulation breakdown o Increased current can increase power consumption and waste energy Jam: Current draw to motor exceeding normal operating conditions (similar to thermal overload) Causes o Mechanical stall, jam, or seizure of the motor / motor load Results o Motor continues to try and drive load (which now has more resistive force) Increased current o Insulation breakdown o System failure 9 9

10 Fault Condition Overview Motor Protection Ground Fault: A fault from line to ground Causes o An unintentional current leakage path to ground in the system Results o Left undetected, can burn through multiple insulation windings o Over time can lead to motor failure Voltage Imbalance: Uneven voltage between phases in a 3-Phase system Causes o Unbalanced single-phase loadings on the three-phase system o Unequal three-phase loads o Poor line conditions or current unbalance Results o Overheating in the motor / reduced insulation life o Reduced motor efficiency 10 10

11 Fault Condition Overview Motor Protection Current Imbalance: Uneven currents between phases in a 3-Phase system Causes o Unbalanced single-phase loadings on the three-phase system o Unequal three-phase loads o Poor line conditions Results o Overheating in the motor / reduced insulation life o Reduced motor efficiency Phase Loss: When one of the (3) phase-currents is not present (single-phasing) Causes o Loose wires, improper wiring o Grounded phase, open fuse, etc Results o Unwanted motor vibrations o Additionally all the results from imbalanced phases 11 11

12 Fault Condition Overview Motor Protection Frequency Variance: When the incoming line frequency is not consistent Causes o Malfunctioning alternator speed regulator o Poor line quality - overloaded supply Results o Increased losses in the system / reduced motor efficiency o Interference with synchronous devices Monitoring ONLY Phase Reversal: Improper wiring leading to phases being connected incorrectly Causes o Miswired motor o Inadvertent phase reversal by the utility Results o Unwanted directional rotation of the motor o Significant mechanical failure and/or operator injury 12 12

13 Fault Condition Overview Load Protection Breaker/Fuses There are several fault characteristics in a system that can lead to pump/load failure Some common causes of pump failure include: Deadhead, cavitation, water-hammer, starved pumps, stalled pumps, etc Contactor Overload Relay Understanding the characteristics of each condition allows the user to reduce troubleshooting time Proper application of motor protection products allows for early indication and prevention of load failure Undercurrent / Low-Power High-Power 13 13

14 Fault Condition Overview Load Protection Undercurrent / Low-Power: Average rms current provided to the motor falls below normal conditions Causes o A portion of the load disappears Undercurrent ONLY o Broken belt, dry pump, dead-headed pump Results o Mechanical failure can (and maybe already has) occurred o Pumping case excessive heating causing seal failure High-Power: The motor load is drawing more power than it should under normal operating conditions Causes o Typical in batch processing applications o Viscosity increases in mixing applications Results o Batch of material that does not meet specifications o Increased power consumption resulting in wasted energy 14 14

15 Fault Condition Overview Line Protection There are several fault characteristics in a system that can lead to poor line conditions Breaker/Fuses Contactor Understanding the characteristics of each condition allows the user to reduce troubleshooting time Proper application of motor protection products allows for early indication and prevention starting motors into poor line conditions in addition to taking motors offline if a line condition appears Overvoltage Undervoltage Overload Relay 15 15

16 Fault Condition Overview Line Protection Overvoltage: When the line voltage to the motor exceeds the specified rating Causes o Poor incoming line quality Results o Lower than rated current draw and a poor power factor o Exceeded insulation ratings Undervoltage: When the line voltage to the motor falls below the specified rating Causes o Poor incoming line quality Results o Leads to excessive current draw o Increased heat in motor windings o Shortened insulation life 16 16

17 Overload Relay Overview Thermal Overloads Electronic Overloads Technology Features Uses a strip composed of tw o different metals w ith differing thermal characteristics Current passes directly through the elements When heated, metals expand at different rates causing the strip to w arp and trip the circuit Can be "fixed" or "adjustable" (1.6:1) Need numberous relays to cover full FLA range Microprocessor based trip time calculations utilize thermal memory tables Heaterless design that monitors current Integral design - no external CT or module Adjustable FLA Cover entire FLA range w ith a few devices Different heater elements requred for Class 10 or 20 Selectable trip class (10A, 10, 20, 30) Thermal Overload and Current Unbalance Protection only Numerous protection modes depending on model Not very accurate Very accurate and reliable 17 17

18 Overload Relay Overview Which has more capability? 210 Thermal Overload Relays or 5 Eaton Electronic Overload Relays You can actually cover more with 5 C440 / XTOE electronic overload relays than with 210 thermal overloads. How can this be? Add up all the thermal overload relays it would take to cover 0.3 to 100 amps, class 10, class 20, class 30, class 10A, automatic reset, and manual reset. It would take 214 different thermal overload relays! Eaton s C440 / XTOE electronic overload relays allow you to select these options right on the face of every overload. Imagine the amount of applications you can cover with just a handful of inventory

19 Eaton Overload Relay Overview Good, Better, Best 2010 Performance Freedom C306 Thermal A 2010 Current product GAP, C440 Electronic Overload Electronic with Ground Fault 0.3 and A Communications C440 Electronic A Communicating Ground Fault XT PKE Electronic A C441 Motor Insight Energy Monitoring Motor and Pump Protection Advanced Diagnostics 1-540A 2010 XT SmartWire Communicating A XT Thermal A XT XTPR Thermal A Price 19 19

20 C441 Motor Insight Advanced Solid-State Overload Relay 20 20

21 Customer Value Message The Motor Insight, the first product in Eaton s Intelligent Power Control Solutions family, is a highly configurable motor, load, and line protective device with power monitoring, diagnostics and flexible communications allowing the customer to save energy, optimize their maintenance schedule, and configure greater system protection extending equipment life, thus reducing overall costs and downtime 21 21

22 Motor Insight C441 Amperage Range FLA Ranges w/cts Motor coverage from amps with only 2 part numbers Vac

23 Motor Insight C441 Family Overview 6 line-powered relays (240, 480, 600 VAC & FLA) 2 control powered (120 vac) blind relays (1-540 FLA, VAC) 2 control powered (120 vac) High-Voltage (1000VAC) relays Modbus RTU (w/ w/o 24 vdc or 120 vac IO) DeviceNet (w/ 24 vdc or 120 vac IO) Profibus (w/ 24 vdc or 120 vac IO) Modbus TCP (w/ 24 vdc or 120 vac IO) Ethernet IP (w/ 24 vdc or 120 vac IO) Remote Display NEMA 1, R Kit HMi software for monitoring/controlling numerous relays 23 23

24 Target Markets and Applications Due to Motor Insight s advanced configurability, monitoring, communications, and protective features, target applications include critical motors and loads, and hard to access motors and loads Additionally, there is a focus on pumping applications due to the power/load capabilities of the product. I.e the ability to sense low suction heads and dead-head situations Target Markets Oil & Gas/Irrigation Water & Wastewater Mining Metals Processing Industrial / Continuous Process Campuses Pulp & Paper Heavy Machinery Applications Coal Bed Methane Wells Submersible Pumps Centrifugal Pumps Belt/Chain Driven Loads Low Speed Mixers Remote Loads in hard to access areas Rail grinders/rock crushers Previously failed motors to help with diagnostics 24 24

25 C441 Protection Features MOTOR PROTECTION Thermal Overload Jam Ground Fault Voltage Imbalance Current Imbalance Phase Loss Frequency Variance Phase Reversal LINE PROTECTION Overvoltage Undervoltage LOAD PROTECTION Undercurrent Low-Power High-Power 25 25

26 C441 Capabilities Load Protection Under-Current (10-90% of FLA) Low Power (kw) (pump protection) High Power (kw) Line Quality Protection Over voltage ( V) Under voltage ( V) Voltage Imbalance (1-20%) Alarm or Trip Motor Protection Overload Jam/Stall/Current (50-400% of FLA) Current Unbalance (1-30%) Current Phase Loss (60% fixed) Ground Fault Current (as low as 0.15 A) Phase Reversal (ignore, ABC, ACB) Monitoring Parameters Current Per Phase and Average RMS Current Unbalance Percent Ground Fault Current Voltage Per Phase and Average RMS Voltage Unbalance Percent Power (observe energy consumption) Power Factor (identify poor pf) Frequency Motor Run Hours Motor Starts (eliminate counters) Thermal Capacity Advanced Features Individual Trip Delays on All Protection Settings Configurable Start Cycle (1-180s) High Inertia or Soft-started loads Multiple Backspin/Reset Timers and # Attempts Lockable User Interface Motor starts and run hours eliminates other components Power-Up Delay Line Quality and GF Alarm and/or Trip modes Isolated and Programmable Contacts for Fault Prioritization 120 Control Power Version Only Built in Electronic Reset or Network Reset Last 10 fault queue diagnostics with full word explanation 1200volt Motor Insight HVR / 1200volt Mining version (-HVR) 26 26

27 Motor Insight C441 Programmable Contacts Feature Independently programmable relay contacts on control powered version only Benefit Independently assign faults to either the 95/96 or the 97/98 Fully Programmable for independent actuation Allows for non fieldbus users to get fault indication without taking the motor offline Allows for importance weighting to fault types GF shunt can be performed without a dedicated GF shunt relay 95/96 (High Priority Motor Stops) Overload Low Under-Current Power Jam/Stall/Current Ground Fault Shunt Current Phase Unbalance Loss Phase High Power Reversal Over voltage Under voltage Voltage Imbalance Assignable 97/98 (Lower Priority Motor Stays Online) Low Under-Current Power Jam/Stall/Current Ground Fault Shunt Current Phase Unbalance Loss Phase High Power Reversal Over voltage Under voltage Voltage Imbalance 27 27

28 C441 Motor Insight Online Monitoring 28 28

29 Online Monitoring Department of Energy on Critical Loads Industrial Motor Populations 0.2% 0.7% 1.8% 0.1% 2.9% 9.1% 1-5 The U.S. manufacturing sector has almost 32,000,000 motors rated 500HP or less % 58.8% Of the 141,000 motors driving pumps, fans, and compressors in critical processes, only 1% of those have online monitoring today (typically >200hp) 40, , , , , , , , Critical Motor Count Estimate Fan Pump Compressor Unscheduled downtime results in: Reduced throughput Environmental fines Higher maintenance costs Increased capital expenditure Reduced profitability 29 29

30 Online Monitoring Critical pumps at various horsepower ranges 9000 Pump Horsepower Distribution (Please indicate the number of (total/critical) pumps on each horsepower range below) Non-critical Critical hp hp hp hp More than 500hp Source: Eaton Survey in Motor Diagnostics and Motor Health News 30 30

31 Overload Relay Solution Monitoring Monitoring Features C441 C440 C306 Thermal Capacity X X Phase Currents X X Current Unbalance X X Ground Fault Current X X Voltage Unbalance X Phase Voltages X kw X Power Factor X Frequency X Run Hours X Motor Starts X Time to Restart X 31 31

32 Overload Relay Solutions Remote Monitoring Modbus RS-485 CANOpen DeviceNet Profibus DP Modbus TCP EtherNet/IP BacNet BAS Communications Webserver Capabilities Power Xpert Connectivity MMAX X X* X* X* SVX X X X X X X X X SPX X X X X X X HMAX X X X S611 X X X X X X X S811 X X X X X X* X* C441 (Motor Insight) X X X X X X X C440 / XTOE X X X X X X X

33 Monitoring Benefit - Maintenance Optimization May 2009 Control Engineering, Sheboygan WWTP Pre Motor Insight Maintenance Practice: Limited operational information required weekly inspections of motors and pumps in hard to access areas 30 FEET DOWN! Inspection required 2 personnel due to OSHA regulations Listened to operating noise No pre-notion of problems that could be occurring, so individual may be over or underqualified for issue at hand No pre-notion of problems that could be occurring, so tools at site may be inappropriate thus requiring multiple trips to site Motor Insight Value Add: MAINTENANCE OPTIMIZATION Eliminating Unnecessary Inspections: Knowledge of real-time data along with 10 history fault-queue enables for sending personnel only when data from Motor Insight indicates an issue Optimizing Labor Skill Sets: Understanding of fault-type allows for appropriate maintenance personnel selection. Having the right man for the job enables the plant to better utilize skill sets reducing wage rates per service trip I.e. don t send your 40-year maintenance person to clear a clog Reducing Service Time: Understanding of fault-type allows for proper tool selection before heading to site, avoiding costly second trips and reducing service time Pre-Motor Insight: 50 service trips/year * 2 labor heads * $40/hr * 2 hours/service trip = $8,000/yr Post-Motor Insight: 15 service trips a year * 2 labor heads * $30/hr * 1 hour/service trip = $900/yr 33 33

34 + db stator current pre-fault post-fault Pump, Motor, Line Quality Protection & Diagnostics with C440 and C441 Overload Relay 34 34

35 Summary of Overload Offering Protection Protective Features C441 C440 C306 Thermal Overload X X X Phase Loss/Imbalance X X X Selectable Trip Class X X Ground Fault X X Current Unbalance X X Voltage Unbalance X Phase Reversal X Stall/Jam X Under/Over Power Trip X Under/Over Voltage Trip X Under/Over Current Trip X 35 35

36 Motor Insight C441 can see the load Breaker/Fuses Contactor C441 looks at 3 phase voltage and current to calculate power kw based OLR allows for monitoring of pump performance kw based OLR allows for protection of harmful conditions to pumps Overload Relay Motor Pump 36 36

37 Pump Protection Low Power Definition: power provided to the motor falls below normal operating conditions Source: A portion of the user's load disappears, caused by a broken belt, a drypump (low suction head), or a dead-headed centrifugal pump. Result: Mechanical failure can or has occurred. Running a pump dry or running a pump in a dead-headed condition can cause excessive heating, damaging expensive seals and ultimately failing the pump Motor Insight s Protective Capability Low Power protective fault settings Low Power is a more consistent way of ensuring detection as power is linear with motor load, where as current is not Configurable trip delays 1-60 seconds 37 37

38 Pump Protection Deadhead / Starved / Dry-Running / Stalled Power (kw) = (Flow x Head x Specific Gravity) / (367 x Efficiency) Motor Insight, detects low power draw and trips the motor 38 38

39 The Power of Diagnostics Diagnostics Motor Insight stores the last 10 faults (best in class) in a non-volatile memory The fault queue is available locally, through the remote display, and through communications Full word descriptions with units on the user interface makes interpretation and setup a breeze More Diagnostics Available with Motor Insight HMi Time-stamping faults Recording more than the last ten faults F.14 is a Jam Fault, No Deciphering of Fault Codes is Needed! 39 39

40 Diagnostics Limited Capability with Standard Overloads Reduces Productivity Bi-metal and Electronic Overload Relays - Fault Indications Possible Cause Possible Cause of the Possible Cause Thermal Overload Trip Only (note: electronic overloads can trip for current unbalance and single phasing, however there is no separate indication, so all faults appear as thermal overload) Number of Possibilities Thermal Overload Worn motor bearings 1 Worn pump bushings 2 Increase in motor load 3 Undersized motor 4 Jam Mechanical interference with motor 5 Mechanical interference with driven load 6 Current Unbalance Phase-to-phase leakage path 7 Unbalanced voltage from poor line quality 8 Single-Phasing Loose wire 9 Improper motor wiring 10 Grounded phase 11 Open fuse 12 Voltage Unbalance Poor incoming line quality 13 Under Voltage Poor incoming line quality 14 High Power Dead-head positive displacement pump 15 Change in process materials 16 Ground Fault Line to ground leakage path 17 Number of Inspections required if using a bi-metal or electronic overload =

41 Diagnostics Superior Capability Provides Productivity Gains Motor Insight - Fault Indications Possible Cause Number of Possibilities Thermal Overload Worn motor bearings Worn pump bushings Increase in motor load Undersized motor 4 Single Phasing Loose wire Improper motor wiring Grounded phase Open fuse 4 Jam Trip Mechanical interference with motor Mechanical interference with driven load 2 Current Unbalance Phase-to-phase leakage path Unbalanced voltage from poor line quality 2 Ground Fault Line to ground leakage path 1 High Power Dead-head positive displacement pump Change in process material properties 2 Under Voltage Poor incoming line quality 1 Voltage Unbalance Poor incoming line quality 1 Over Voltage Poor incoming line quality 1 Phase Rotation A mis-wired motor Inadvertent phase reversal by the utility 2 Under Current Change in the load: broken belt, low suction head, dead-headed centrifugal pump Rise in line voltage 2 Under Power Change in the load: broken belt, low suction head, dead-headed centrifugal pump 1 Average number of inspections required if using a Motor Insight Overload and Monitoring Relay =

42 + db stator current pre-fault post-fault Pump, Motor, Line Quality Energy Savings with C441 Overload Relay 42 42

43 Energy Savings In the U.S. motors use 71% of the electrical energy in a typical industrial facility Motor System Energy Use (GWh/YR) Large population of motors in the hp range consuming the majority of energy 70, , , , , Compressor Pump Fan 20, Very little condition monitoring done on low horsepower motors <1% 10,

44 Energy Savings Power Monitoring with C441 Motor Insight Eaton s C441 Monitors (data/warning) Current Per Phase and Average RMS Current Unbalance Percent* Ground Fault Current* Voltage Per Phase and Average RMS Voltage Unbalance Percent* Power Power Factor Avoid Peak Demand Charges Frequency* Motor Run Hours* Shed non-vital loads Thermal Capacity Identify and rectify increased consumption Identify discrepancy between equal loads Identify Loads with Poor Power Factor 44 44

45 Motor Insight Success Energy Savings May 2009 Control Engineering, Sheboygan WWTP Scenario: Three 480V 75 hp, 96 amp tripping-current motors at Indiana Ave lift station Customer was previously only monitoring flow to detect problems Flow was the same for all three pumps, however with Motor Insight they observed pump 3 drawing abnormal current due to a foreign object on the impeller Motor Insight - Value Add: ENERGY SAVINGS Motor Insight s advanced monitoring capability and flexible communications capability allowed the plant to observe this abnormal operation in real-time Motor 1 Draws 60 amps Motor 2 Draws 60 amps Motor 3 Draws 90 amps They sent maintenance personnel immediately upon observation and removed the foreign object sqrt 3*14.4 kw*$0.10/kw-hr *24 hours/day*7 days/weeks*26 weeks/year = $10,894 of wasted energy 45 45

46 Summary C441 Overload Relay Benefits Monitoring Benefits Data for control industrial protocols, control circuits and registers allow for data to drive action locally or at a system level Optimized labor practices from routine inspections to data driven, targeted inspections Protection Benefits Reduced Capital Expenses Pump failures from deadhead and dry conditions Submersible pump/motor failure from poor line conditions Advanced motor protection prevent failure on troublesome compressors Diagnostics Benefits Reduced Downtime Reduction in inspection points means you are up and running faster Specific trip indication means you get it right the first time with less repeats Energy Savings Benefits Avoid Peak Demand Charges Shed non-vital loads Identify and rectify increased consumption Identify discrepancy between equal loads Identify Power Factor Line Items 46 46

47 Competitive Value Messages Highly Configurable Line, Load, and Motor Protection and Monitoring Fault trip and reset behavior configurable by fault type 10 Monitoring Choices Reliability and Improved Uptime Enhanced surge and sag withstand capacity Robust design suited for applications with high line conditions and poor power quality Communications Flexibility Multiple communication modules Can use the communications module and remote display at the same time Better Diagnostics 10 fault queue available locally Local interface and monitoring Safety Terminal Block IP20 rated terminal block Terminal blocks are set back from the display to reduce operator shock hazard Optional Remote Display Ease of Use Allows for configuration from outside of the panel Bright LED display with easy to understand settings and references Type 1 Remote display has the same user interface as the base unit device Adjustments to overload settings can be made without disconnecting power Line-powered design Reduced Inventory 50% less sku s compared to competition 6 total style numbers provides: VAC VAC FLA amps 47 47

48 Questions