E.S.P. Embedded Sensing Probes for Motor Brushes

E.S.P. Embedded Sensing Probes for Motor Brushes 2/13 Installation & Operating Manual MN609

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Table of Contents 1.0 Introduction...1 2.0 General Information...1 3.0 Description of Equipment...1 4.0 Equipment List...1 5.0 Installation...2 6.0 Connection Instructions...8 7.0 Application Guidelines...8 8.0 Troubleshooting...8 9.0 E.S.P. Brush Monitor... 9 i

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1.0 Introduction This manual contains information on the proper installation, maintenance and operation of the E.S.P. brush monitor system. A complete description of equipment, application guidelines, troubleshooting guide, connection instructions and a list of replacement parts are included. 2.0 General Information The purpose of the E.S.P. brush monitor system is to provide an automatic early warning of the need to replace brushes on DC motors and generators, regardless of the manufacturer. Unique patented E.S.P. brushes contain Embedded Sensing Probes providing a short brush signal when the brushes approach the end of their useful life. At that point, enough brush life remains so that brush replacement may be scheduled within a reasonable amount of time. The E.S.P. monitor, upon receiving the short brush signal, illuminates a red warning light and energizes a relay which may be connected to an external device such as an audible alarm. The E.S.P. brush monitor system reduces maintenance cost by eliminating visual inspections of brush length, protects equipment against costly damage, and guards against equipment downtime and lost production. 3.0 Description Of Equipment The E.S.P. brush monitor system consists of an electronic brush monitor, a matched set of E.S.P. brushes and standard brushes, E.S.P. signal and signal return isolation networks and accessories for installation. Each E.S.P. brush monitor system is designed to be used in conjunction with DC motors and generators with armature voltages from 90 up to 1000 volts DC operating on generated DC or rectified power source. E.S.P. brushes are equipped with patented Embedded Sensing Probes and are mounted in the motor. A minimum of one E.S.P. brush per pole is required. These brushes provide an electrical output signal to the E.S.P. monitor when an E.S.P. probe comes into contact with the commutator and a minimum of 10% rated voltage is applied to the armature. The probe depth is determined by the design and construction of the brush and brushholder. A current limiting isolation network mounted within the motor or the motor terminal box connects the E.S.P. brushes to the E.S.P. monitor. There are two ESP Brush Monitors available. One is designed to monitor a single motor, providing for maximum flexibility in location as well as the simplest possible installation. The other design monitors up to six motors having any combination of armature voltages through 1000 VDC. Each monitor is packaged in a wall-mounted NEMA 4 enclosure and is powered by 115 volts AC 50/60 Hz. All monitors are equipped with green pilot lights to indicate that each monitor circuit is on and functioning properly. A red warning light and relay for each monitored motor actuates in response to the E.S.P. signal from the E.S.P. brushes. A push to test feature provides a momentary signal to the input of the E.S.P. monitor and allows a means to test the operation of the red warning lamp and relay for each circuit. The E.S.P. signal is a low level signal (current limited to 5mA, by the motor-mounted current limiter isolation network) and, as such, should be wired to the monitor using signal wiring techniques. Should you choose to mount this monitor in or close to the motor control, this signal wire should be routed from the motor terminal box to the monitor along with motor armature leads in the armature power wire conduit or wire tray. A signal return is provided by a second current limiting isolation network connected across A1 and A2. This circuit may be mounted in the control cabinet. See Figure 1. Figure 1 Connection Diagram for Normal Installation Of E.S.P. Monitor This circuit may be mounted in the motor terminal box along with the E.S.P. isolation network. A twisted pair must be used to connect the E.S.P. signal and signal return to the monitor. See Figure 2. Figure 2 Alternate Connection Diagram for Remote Mounting Of E.S.P. Monitor A matched set consisting of E.S.P. and standard brushes constructed of the same carbon material and grade must be procured as a complete set from Baldor. 4.0 Equipment List Purchased from Baldor: 1. E.S.P. Monitor 2. E.S.P. Signal Isolation Network (See Table 1) (including extra wire, connectors and splices which may be required in certain applications as indicated in this instruction manual). 3. Signal Return Isolation Network (See Table 1) 4. Complete set of E.S.P. and Standard Brushes. Supplied by User: 1. Signal Wire- #16 AWG Minimum, 600 Volt, and Class B (105 C) for systems up to 600 armature voltage or #16 AWG minimum 1000 volt and Teflon insulated (200 C) 1

for systems with 601-1000 armature voltage. The available systems cover a wide range of DC armature voltages from 90 through 1000 volts. Use applicable E.S.P. signal and signal return isolation networks as indicated in Table 1. Table 1 Armature Voltage Number of Poles Maximum No. of E.S.P. Brushes E.S.P. Signal Isolation Network Signal Return Isolation Network 91 v 2 or 4 4 418230-1RD 608808-56R 91-250 v 2 or 4 4 418230-1S 608808-56S 91-250 v 2, 4 or 6 8 418230-1RB 608808-56S 91-250 v 2, 4 or 6 12 418230-1RC 608808-565 91-250 v 6 18 418230-1RD 608808-565 251-600 v 2, 4 or 6 8 418230-lT 608808-56T 251-600 v 2, 4 or 6 12 418230-1V 608808-56T 251-600 v 2, 4 or 6 18 418230-1RA 608808-56T 601-1000 v 4, 6 or 8 24 418230-65 609650-A Warning: Before attempting to install this E.S.P. brush monitor system, disconnect and lockout all sources of incoming power to the control and motor. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this equipment. 5.0 Installation The installation procedures vary slightly between the single motor monitor unit and the six motor monitor unit. To assure proper installation refer to the following sections: Single-Motor Monitor - see 5.1 to 5.5 Multi-Motor Monitor- see 5.6 to 5.10 5.1 Installation Of Single Motor Monitor 1. Disconnect and lock out all incoming drive power to the control and motor. 2. Determine the installation pattern of the E.S.P. brushes and standard brushes using Table 2 as a guide. Table 2 Important note: If brush mountings have been altered to allow for brush staggering, brushes on adjacent poles must be installed in the same track (See Figure 3). Figure 3 3. There are two different isolation networks (E.S.P. signal isolation network and the signal return isolation network) which must be installed. There are two ways to install each type of network. First determine your application then refer to the proper installation procedure. E.S.P. Signal Isolation Network This network may be installed in the motor terminal box (see Figure 4) with the two E.S.P. signal isolation network leads (marked W+ and W-) extending into the motor, around the frame and connecting to the E.S.P. brush probe leads or it may be installed inside the motor frame (see Figure 8) with the output lead (W1) extending into the motor terminal box. After selecting the mounting method, refer to the appropriate installation procedure as follows: Mount E.S.P. Signal isolation network in motor terminal box- see 5.2 Mount E.S.P. Signal isolation network inside the motor frame - see 5.3 Signal Return Isolation Network The signal return isolation network may be connected in the motor terminal box (see 5.4) or it may be connected to the motor controller (see 5.5). 2

5.2 Instructions For Mounting E.S.P. Signal Isolation Network In Motor Terminal Box 1. Remove top and side hand hole covers. 2. Remove all existing brushes from motor and discard. 3. Replace one or more brushes as required on each stud with new E.S.P. brushes equipped with embedded sensing probes (see Table 2). Then complete the set with additional new standard brushes of the same grade material. 4. Use Plastic Ties provided to secure E.S.P. brush probe leads to top field coil or motor wire harness with lead tie as required. Provide sufficient slack in E.S.P. brush probe lead to allow for brush wear as brush moves down in brushholder box. 5. Secure E.S.P. signal isolation network in terminal box. Then run leads W+ and W- into motor frame (see Figure 4). 6. Cut W+ and W- leads as necessary, leaving sufficient length to reach each E.S.P. brush probe lead, allowing for slack. Strip wire, and crimp-on the male connectors provided. 7. Connect E.S.P. signal isolation network leads to E.S.P. brush probe leads per connection diagram (see Figure 5). For example: On 2 pole motors connect 1 positive E.S.P. brush probe lead to lead on E.S.P. signal isolation network marked W+, and 1 negative E.S.P. brush probe lead to lead on E.S.P. signal isolation network marked W-. On 4, 6 or 8 pole machines, there are 2-, 3 or 4 positive leads and 2, 3 or 4 negative leads respectively. On motors with 4, 6 or 8 poles, or more than one E.S.P. brush per stud, the E.S.P. brush probe leads shall be connected to the E.S.P. signal isolation network leads per Figure 6 or Figure 7. Figure 4 3

E.S.P. Brush Probe Lead Connection Diagram For E.S.P. Signal isolation network wiring instructions, refer to wiring diagrams. Figure 6 and Figure 7. Figure 5 Figure 6 4

Figure 7 Caution: Assure that E.S.P. brush probe leads from positive and negative poles are not inter-connected. This can cause line to line shorting of the motor, resulting in damage to control equipment and the E.S.P. monitor. 8. Connect E.S.P. signal lead (marked W1) to additional signal wire and run to E.S.P. monitor and connect at terminal 102 (additional signal wire to be provided by user). 9. Replace top and side hand hole covers. Record part numbers of E.S.P. and standard brushes on motor label 418258-5A (as provided) and adhere to hand hole cover. 10. Install Signal Return Isolation Network see 5.4 or 5.5 (Single Motor Monitor) or See 5.6 (Multi Motor Monitor). Warning: Attempting to use E.S.P. Brushes without the network will place armature power limited only by the capabilities of the drive control on to the E.S.P. Output signal lead which can result in personal injury and/or equipment damage. Confirm that the motor has been equipped with an E.S.P. isolation network. This network which may be either fastened to the motor frame or mounted in the motor terminal box, received input from the E.S.P. brushes (minimum one per stud) and provides, as its output, a signal indicating a short brush condition of any E.S.P. Brush. Its output is a single wire mark e d W1. This network limits the output current on W1 to a maximum of 5 milliamperes under either normal or fault conditions. 5

Instructions for mounting signal return isolation network to the motor controller -see 5.4 Instructions for mounting signal return isolation network in motor terminal box. -see 5.3 Figure 8 Motor Terminal Installation Box (2 Pole Motor Illustrated) 5.3 Instructions For Mounting E.S.P. Signal Isolation Network In Motor Frame 1. Remove top and side hand hole covers. 2. Remove all existing brushes from motor and discard. 3. Replace one or more brushes as required on each stud with new E.S.P. brushes equipped with embedded sensing probes (see Table 2). Then complete the set with additional new standard brushes of the same grade material. 4. Use plastic ties provided to secure brush monitor E.S.P. signal isolation network to top field coil or motor wire harness with lead ties as required (see Figure 4). 5. Bring single lead (marked W1) from E.S.P. signal isolation network into motor terminal box. Then connect additional signal wire and run E.S.P. signal lead to E.S.P. monitor and connect at terminal 102 (additional signal wire to be provided by user). 6. Cut W+ and W- leads as necessary, leaving sufficient length to reach each E.S.P. brush probe lead, allowing for slack. Strip wire, and crimp-on the male connectors provided. 7. Connect E.S.P. brush probe leads to E.S.P. signal isolation network leads per connection diagram (see Figure 5). For example: On 2 pole motors, connect 1 positive E.S.P. brush probe lead to lead on E.S.P. signal isolation network marked W+, and 1 negative E.S.P. brush probe lead to lead on E.S.P. signal isolation network marked W-. On 4, 6, or 8 pole machines there are 2, 3 or 4 positive leads and 2, 3 or 4 negative leads respectively. On motors with 4, 6, or 8 poles, or more than one E.S.P. brush per stud, the E.S.P. brush probe leads shall be connected to E.S.P. signal isolation network leads per Figure 6 or Figure 7. 8. Make sure all E.S.P. probe leads and E.S.P. signal isolation network leads are tied in such a manner so they will not get tangled in any rotating parts. Provide sufficient slack in E.S.P. brush probe lead to allow for brush wear as brush moves down in brushholder box. 9. Replace top and side hand hole covers. Record part numbers of E.S.P. and standard brushes on motor label 418258-5R (as provided) and adhere to hand hole cover. 10. Install Signal Return Isolation Network see 5.3 or 5.4 (Single Motor Monitor) or 5.6 (Multi-Motor Monitor). Instructions for mounting signal return isolation network in motor Terminal box. - see 5.4 Instructions for mounting signal Return isolation network to motor controller - see 5.5. 6

5.4 Instructions For Mounting Signal Return Isolation Network In Motor Terminal Box Install the E.S.P. signal return isolation network in the motor terminal box using the following procedures (see Table 1 for part number). 1. Connect leads marked A1 and A2 to armature leads in terminal box. 2. Secure signal return isolation network inside the motor terminal box using plastic ties #69306-3F as necessary. 3. Run signal return lead and E.S.P. signal lead as twisted pair to E.S.P. monitor (see Figure 2). 4. Connect E.S.P. signal lead (marked W1) to terminal 102 and signal return lead to terminal 101. 5.5 Instructions For Mounting Signal Return Isolation Network To Motor Controller Install the E.S.P. signal return isolation network in the control using the following procedures (see Table 1 for part number). 1. Connect leads marked A 1 and A2 to terminals A1 and A2 in motor controller. Refer to Figure 9. 2. Secure network to inside cabinet or panel using #69306-3X anchors and plastic ties #69306-3F as required. 3. Run signal return lead to E.S.P. monitor and connect at terminal 101 (see Figure 1). 5.6 Installation Of Multimotor Monitor If you have purchased a Multi-Motor Monitor from Baldor, you will be able to monitor up to six (6) motors of varying armature voltages through 1000 VDC. 1. Disconnect and lock out all incoming drive power to the control(s) and motor(s). 2. Determine the installation pattern for each motor of the E.S.P. brushes and standard brushes using Table 2 as a guide. 3. There are two different isolation networks (E.S.P. signal isolation network and the signal return isolation network) which must be installed. There are two different ways to install each type of network. Therefore, first determine your application and then refer to the referenced installation procedure. E.S.P. Signal Isolation Network This network may be installed in the motor terminal box (see Figure 4) with the two E.S.P. signal isolation network leads (marked W+ and W-) extending into the motor, around the frame and connecting to the E.S.P. brush probe leads or it may be installed Inside the motor frame (see Figure 8) with the output lead (W1) extending into the motor terminal box. After selecting the mounting method, refer to the appropriate installation procedure as follows: Mount E.S.P. signal isolation network in motor terminal boxsee 5.2 Mount E.S.P. signal isolation network inside the motor framesee 5.3 5.7 Instructions For Mounting The E.S.P. Signal Isolation Network In The Motor Terminal Box Repeat 5.2 for each motor to be monitored. 5.8 Instructions For Mounting The E.S.P. Signal Isolation Network In The Motor Frame Repeat 5.3 for each motor to be monitored. 5.9 Instructions For Mounting The E.S.P. Signal Isolation Network In The Motor Terminal Box Repeat 5.4 for each motor to be monitored. 5.10 Instructions For Mounting The E.S.P. Signal Isolation Network In The Drive Controller Repeat 5. 5 for each motor to be monitored. Figure 8 E.S.P. Brush Monitor System Connections SIGNAL RETURN ISOLATION NETWORK The signal return isolation network may be connected in the motor terminal box (see 5.4) or it may be connected to the motor controller (see 5.5). 7

6.0 CONNECTION INSTRUCTIONS 1. To verify the proper operation of the E.S.P. signal current limiter isolation network, disconnect leads on the E.S.P. signal isolation network. Using a conventional ohmmeter, measure the resistance from W+ to W1, then W- to W1. The resistance values should read as follows: Rated Armature Voltage 90 VDC 91-250 VDC 251-600 VDC 601-1000 VDC Resistance Measured 20KΩ ± 10% 56KΩ ± 10% 220KΩ ± 10% 360KΩ + 10% Reconnect the E.S.P. signal isolation network lead(s) disconnected to perform this test. 2. Confirm that the E.S.P. signal wire and signal return wire have been routed from the motor to the E.S.P. monitor. Refer to 4.0 equipment list for proper wire specification. If the signal return network is mounted in the motor or motor terminal box, the signal and signal return leads must be a twisted pair to the E.S.P. monitor. 3. Connect 115VAC line to monitor terminals 188 and 189. 4. If used, the monitor output relay can be wired from the monitor into customer circuitry using terminals 241, 242 and 243. Terminal 242 is a common connection. Terminal 241 provides a normally closed contact. Terminal 243 provides a normally open contact (see Figure 9). NOTE: If the power source brought to the contacts of this relay remains energized even with main input power to the cabinet disconnected, wiring to the relay contacts must be done with yellow wire to indicate a foreign circuit source. A warning legend plate, indicating that these auxiliary contacts receive power from a source not disconnected with the disconnection of main incoming drive power, has been provided with this system. This legend plate, required by N.E.C., must be mounted on the door of the drive cabinet. If an incoming line circuit breaker with a thru-the-door operating handle has been installed into the drive, this legend plate should be mounted near the breaker. 5. A push to test feature provides a momentary signal to the input of the E.S.P. monitor and allows a means to test the operation of the red warning lamp and relay. 8.0 Troubleshooting In the event that neither the green pilot light or the red warning light are illuminated on the monitor, one of three conditions may exist: 1. No 115 volts AC power. Check power source. 2. Either one or both lamps have failed. Check and/or replace bulb(s). Lamp Replacement: To replace lamp(s), unscrew red or green lens and remove bulb(s) from lens cavity. Replace with a standard #327 bulb, then reinstall red or green lens in monitor. Care should be exercised to ensure 0 ring seal on lens is not damaged. 3. The E.S.P. brush monitor system has malfunctioned. IMMEDIATE ACTION SHOULD BE TAKEN TO ACTIVATE A VISUAL MONITORING SYSTEM AS THE E.S.P. BRUSH MONITOR SYSTEM IS NO LONGER MONITORING BRUSH WEAR. Contact Baldor District Office. Caution: This motor is now equipped for use with an E.S.P. Monitoring System. Replace brushes as necessary with the proper complement of E.S.P. and standard brushes. The E.S.P. system will function only if all carbon brushes in each application are constructed of the same grade of material. All E.S.P. and standard brushes in each application must be procured as a matched set from your Baldor District Office. 7.0 Application Guidelines The user should note the following operating characteristics of the E.S.P. brush monitor system: 1. The short brush signal will occur providing that at least 10% armature voltage is present. The monitor may not provide consistent indication of a short brush condition at armature voltage of less than 10% of maximum. 2. Relay contacts in this system are rated to carry 0.5 amperes resistive or 0.25 amperes inductive current at 120 VAC. When using the relay to energize inductive loads (relay coils, etc.) a suppressor (Baldor P/N 600686-33A or equivalent R-C suppressor) must be wired across the load for contact protection. 3. This monitor does not latch. Armature voltage of 10% or greater must be present for indication to take place. 8

9.0 E.S.P. Brush Monitor Single-Motor Monitor P/N 418258-R Qty. Description Part Number 1 Cover 800756-11A 1 Base 801590-A 1 Cover Gasket 608829-A 1 Hinge Kit K-10 1 Red Lens 609644-A 1 Green Lens 609644-B 2 Light Sockets 410308-14R 2 Lamps 609644-F 1 Pushbuttons 609644-D 1 P/B Seals 609644-E 1 PC Boards 418258-3S 1 Mounting Plate 418258-7A 1 Legend Nameplate 418258-16R 1 Nameplate Gasket 417194-7C 4 Cover Mtg. Screws 410425-9A 1 Caution Label 418258-4A 1 Warning Label 417197-12A 1 Danger Label 417197-11A 1 Motor Label 418258-5A Multi-Motor Monitor P/N 418258-6R Qty. Description Part Number 1 Cover 800756-11A 1 Base 801590-A 1 Cover Gasket 608829-A 1 Hinge Kit K-10 6 Red Lens 609644-A 6 Green Lens 609644-B 12 Light Sockets 410308-14R 12 Lamps 609644-F 6 Pushbuttons 609644-D 6 P/B Seals 609644-E 6 PC Boards 418258-3S 1 Mounting Plate 418258-7A 1 Legend Nameplate 418258-16R 1 Nameplate Gasket 417194-7C 6 Cover Mtg. Screws 410425-9A 1 Caution Label 418258-4A 1 Warning Label 417197-12A 1 Danger Label 417197-11A 6 Motor Label 418258-5A Key 1) Carbon Probe 2) Insulator 3) Carbon Probe Contact Surface 4) Commutator Surface 5) Copper Conductor 6) Motor Brush The contact portion of the Embedded Sensing Probe is a miniature carbon probe (1) covered by an insulating sleeve (2). This insulated sleeve isolates the probe s conductive surface from the current flow in the brush until the carbon probe contact surface (3) engages the commutator surface (4). An insulated copper conductor (5) is, in turn, embedded into the miniature carbon brush. This entire assembly is inserted into the motor brush (6) to a statistically determined depth so that the E.S.P. signal allows you time to schedule brush replacement. Many factors can affect brushwear. Changing environment, humidity, load, variable brushholder spring tension, will all affect actual brushwear. Therefore, Baldor strongly recommends that brush replacement be scheduled at the earliest practical time following the E.S.P. signal. 9

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Baldor Electric Company P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: 479.646.4711, Fax 479.648.5792, International Fax 479.648.5895 www.baldor.com Baldor Electric Company MN609 All Rights Reserved. Printed in USA. 2/13