1 1 4 3 Press Press Press 2 1 Press Press 3 1 Press 2 Press Press 2 Press 1 8 Press Press 7 Press 6 1 2 Press 4 5 Press 3 Press Press Press Press Press 4 3 Press 2 1 Press Automation Products Distribution and Residential Products Power and Logic Control Power Management Panelboards and Switchboards Field Services, Batteries, Part Replacements, Installed Product Support Building Information Modeling (BIM) Technical and Warranty Support Commercial Support Component Warranty & Returns (CORE) 877-ETNCARE 877-386-2273 EatonCare Support: Component Order & Component Returns EatonCare Technical Resource Center EatonCare OEM EatonCare Project Order Support EatonCare Power Quality Press 1 Press 2 Press 3 Press 4 Press 5 General Support Customer Segments Order Expediting & Order Tracking Price, Availability, & Order Status Technical and Warranty Support Commercial Support Power Quality Returns Technical Support Commercial Support Sensors and Limit Switches Vehicle Controls Drives Amy 24/7 Automated Information System
Transcript
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Automation Products
Distribution and Residential Products
Power and Logic Control
Power Management
Panelboards and Switchboards
Field Services, Batteries, Part Replacements, Installed Product Support
Building Information Modeling (BIM)
Technical and Warranty Support
Commercial Support
Component Warranty & Returns (CORE)
877-ETNCARE877-386-2273
EatonCare Support: Component Order & Component Returns
EatonCare Technical Resource Center
EatonCare OEM EatonCare Project Order Support
EatonCare Power Quality
Press
1Press
2Press
3Press
4Press
5
General Support Customer Segments
Order Expediting & Order Tracking
Price, Availability, & Order Status
Technical and Warranty Support
Commercial Support
Power Quality Returns
Technical Support
Commercial Support
Sensors and Limit Switches
Vehicle Controls
Drives
Amy 24/7 Automated Information System
2 2
EatonCare OEM Team
Mission• Maintain premier service levels that exceed our
customers’ expectations and serve as a differentiator for our field sales engineers
3 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
Resultso Increased losses in the system / reduced motor efficiencyo Interference with synchronous devices
Phase Reversal: Improper wiring leading to phases being connected incorrectly
Causeso Miswired motoro Inadvertent phase reversal by the utility
Resultso Unwanted directional rotation of the motoro Significant mechanical failure and/or operator injury
MonitoringONLY
Fault Condition Overview Motor Protection
13 13
• 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
• 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
Contactor
Breaker/Fuses
OverloadRelay
• Undercurrent / Low-Power• High-Power
Fault Condition Overview Load Protection
14 14
Undercurrent / Low-Power: Average rms current provided to the motor falls below normal conditions
Causeso A portion of the load disappearso Broken belt, dry pump, dead-headed pump
Resultso Mechanical failure can (and maybe already has) occurredo Pumping case – excessive heating causing seal failure
High-Power: The motor load is drawing more power than it should under normal operating conditions
Causeso Typical in batch processing applicationso Viscosity increases in mixing applications
Resultso Batch of material that does not meet specificationso Increased power consumption resulting in wasted energy
UndercurrentONLY
Fault Condition Overview Load Protection
15 15
• There are several fault characteristics in a system that can lead to poor line conditions
• 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 appearsContactor
Breaker/Fuses
OverloadRelay
• Overvoltage• Undervoltage
Fault Condition Overview Line Protection
16 16
Overvoltage: When the line voltage to the motor exceeds the specified rating
Causeso Poor incoming line quality
Resultso Lower than rated current draw and a poor power factoro Exceeded insulation ratings
Undervoltage: When the line voltage to the motor falls below the specified rating
Causeso Poor incoming line quality
Resultso Leads to excessive current drawo Increased heat in motor windings o Shortened insulation life
Fault Condition Overview Line Protection
17 17
Thermal Overloads Electronic Overloads
• Uses a strip composed of tw o different metals w ith differingthermal characteristics
• Microprocessor based trip time calculations utilizethermal memory tables
• Current passes directly through the elements • Heaterless design that monitors current• When heated, metals expand at different rates causing the strip to w arp and trip the circuit
• Integral design - no external CT or module
• Can be "f ixed" or "adjustable" (1.6:1) • Adjustable FLA• Need numberous relays to cover full FLA range • 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
Tech
nolo
gyFe
atur
esOverload Relay Overview
18 18
Overload Relay Overview
210 Thermal Overload Relays
5 Eaton Electronic Overload Relaysor
Which has more capability?
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 19
Per
form
ance
Price
Current product GAP, Electronic Overload
with Ground Faultand Communications
XT• Thermal•0.1 - 630A
XT XTPR•Thermal• 0.1 - 65A
XT PKE•Electronic• 0.3 - 65A
2012
XT SmartWire•Communicating• 0.3 - 65A
2010
C441 Motor Insight• Energy Monitoring• Motor and Pump Protection• Advanced Diagnostics• 1 - 540A
C441 Motor InsightAdvanced Solid-State Overload Relay
21 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
22 22
1 9
60 135
120 270
FLA Ranges w/CTs
240 540
• Motor coverage from 1-540 amps with only 2 part numbers
• 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
•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
25 25
C441 Protection Features
MOTOR PROTECTION• Thermal Overload• Jam• Ground Fault• Voltage Imbalance• Current Imbalance• Phase Loss• Frequency Variance• Phase Reversal
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
Load Protection• Under-Current (10-90% of FLA)• Low Power (kW) (pump protection)• High Power (kW)
Line Quality Protection• Over voltage (170-660V)• Under voltage (170-660V)• 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)
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 InsightHVR / 1200volt “Mining” version (-HVR)
C441 Capabilities
27 27
95/96 (High Priority – Motor Stops)• Overload• Low Power• Jam/Stall/Current • Current Phase Loss • Phase Reversal
95/96 (High Priority – Motor Stops)• Overload • Under-Current • Ground Fault Shunt• Current Unbalance• High Power • Over voltage• Under voltage• Voltage Imbalance
97/98 (Low Priority – Motor Stays Online)• Under-Current • Ground Fault Shunt• Current Unbalance• High Power • Over voltage• Under voltage• Voltage Imbalance
97/98 (Lower Priority – Motor Stays Online)• Low Power• Jam/Stall/Current • Current Phase Loss • Phase Reversal
Motor Insight C441 Programmable Contacts
Feature• Independently programmable relay contacts on control powered version onlyBenefit• 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
Assignable
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C441 Motor InsightOnline Monitoring
29 29
• The U.S. manufacturing sector has almost 32,000,000 motors rated 500HP or less
• Of the 141,000 motors driving pumps, fans, and compressors in critical processes, only 1% of those have online monitoring today (typically >200hp)
Online MonitoringDepartment of Energy on Critical Loads
30 30
Source: Eaton Survey in Motor Diagnostics and Motor Health News
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
0-20hp 21-100hp 101-250hp 251-500hp More than500hp
Pump Horsepower Distribution(Please indicate the number of (total/critical) pumps on each
horsepower range below)
Non-critical
Critical
Online MonitoringCritical pumps at various horsepower ranges
31 31
Monitoring Features C441 C440 C306Thermal Capacity X XPhase Currents X XCurrent Unbalance X XGround Fault Current X XVoltage Unbalance XPhase Voltages XkW XPower Factor XFrequency XRun Hours XMotor Starts XTime to Restart X
Overload Relay SolutionMonitoring
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Mod
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-485
CA
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Pro
fibus
DP
Mod
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TCP
Eth
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Bac
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MMAX X X* X* X*SVX X X X X X X X XSPX X X X X X XHMAX X X XS611 X X X X X X XS811 X X X X X X* X*C441 (Motor Insight) X X X X X X XC440 / XTOE X X X X X X X
Overload Relay SolutionsRemote Monitoring
33 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 under-
qualified 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 siteMotor 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
•Post-Motor Insight:15 service trips a year * 2 labor heads * $30/hr * 1 hour/service trip = $900/yr
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Pump, Motor, Line QualityProtection & Diagnostics with
C440 and C441 Overload Relay
0 60 120 180 240 300 360 420 480-10
0
10
20
30
40
50
60
70
80stator current
dB
pre-faultpost-fault
+
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Protective Features C441 C440 C306Thermal Overload X X XPhase Loss/Imbalance X X XSelectable Trip Class X XGround Fault X XCurrent Unbalance X XVoltage Unbalance XPhase Reversal XStall/Jam XUnder/Over Power Trip XUnder/Over Voltage Trip XUnder/Over Current Trip X
Summary of Overload OfferingProtection
36 36
Motor InsightC441 can “see” the load
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
Contactor
Breaker/Fuses
OverloadRelay
Motor Pump
37 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 dry-pump (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
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• Power (kW) = (Flow x Head x Specific Gravity) / (367 x Efficiency)
• Motor Insight, detects low power draw and trips the motor
Voltage Unbalance Poor incoming line quality 13Under Voltage Poor incoming line quality 14High Power Dead-head positive displacement pump 15
Change in process materials 16Ground Fault Line to ground leakage path 17
17Number of Inspections required if using a bi-metal or electronic overload =
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)
41 41
Motor Insight - Fault Indications Possible CauseNumber of
PossibilitiesThermal Overload
4Single Phasing
4Jam Trip
2Current Unbalance
2Ground Fault 1High Power
2Under Voltage 1Voltage Unbalance 1Over Voltage 1Phase Rotation
2Under Current
2Under Power 1
Average number of inspections required if using a Motor Insight Overload and Monitoring Relay = 1.92
Rise in line voltageChange in the load: broken belt, low suction head, dead-headed centrifugal pump
Poor incoming line qualityA mis-wired motor Inadvertent phase reversal by the utilityChange in the load: broken belt, low suction head, dead-headed centrifugal pump
Dead-head positive displacement pumpChange in process material propertiesPoor incoming line qualityPoor incoming line quality
Mechanical interference with driven loadPhase-to-phase leakage pathUnbalanced voltage from poor line qualityLine to ground leakage path
Worn pump bushingsIncrease in motor loadUndersized motorLoose wireImproper motor wiringGrounded phaseOpen fuseMechanical interference with motor
Worn motor bearings
Diagnostics Superior Capability Provides Productivity Gains
42 42
Pump, Motor, Line Quality Energy Savings with
C441 Overload Relay
0 60 120 180 240 300 360 420 480-10
0
10
20
30
40
50
60
70
80stator current
dB
pre-faultpost-fault
+
43 43
• In the U.S. motors use 71% of the electrical energy in a typical industrial facility
• Large population of motors in the 5-300 hp range consuming the majority of energy
• Very little condition monitoring done on low horsepower motors <1%
• Current Per Phase and Average RMS• Current Unbalance Percent*• Ground Fault Current* • Voltage Per Phase and Average RMS• Voltage Unbalance Percent*
• Power • Power Factor• Frequency*• Motor Run Hours*• Thermal Capacity
•Avoid Peak Demand Charges
•Shed non-vital loads
•Identify and rectify increased consumption
•Identify discrepancy between equal loads
•Identify Loads with Poor Power Factor
Energy SavingsPower Monitoring with C441 Motor Insight
45 45
Motor Insight Success – Energy SavingsMay 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 1
Draws 60 amps
Motor 2
Draws 60 amps
Motor 3
Draws 90 amps
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
• 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
46 46
SummaryC441 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
47 47
Competitive Value Messages• Safety
• Terminal Block• IP20 rated terminal block • Terminal blocks are set back from the
display to reduce operator shock hazard • Optional Remote Display
• Allows for configuration from outside of the panel
• Ease of Use• 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 –170-660VAC• FLA – 1-540 amps
• Highly Configurable Line, Load, andMotor 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
