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“5 Ways to Protect your Motor and Increase your
Uptime with Solid-State Overload Relays”
-hosted by Erie Bearings
Adam Krug – Product Manager
Industrial Controls Division, Eaton Corporation
© 2008 Eaton Corporation. All rights reserved.
Training Goals
• Understanding of basic motor protection then and
now
• “5 Ways to Protect Your Motor”
• Leveraging additional capabilities from electronic relays
beyond simple thermal protection to protect motors
• “Protecting your Utility bill”
• Getting onboard the energy monitoring trend with today's
relays
• “Protecting your load/pump”
• Seeing beyond the motor to the actual load with no additional
hardware
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2
Traditional Motor Protection Overview
• Traditional OLR’s monitor 3phase current to simulate
motor winding temperatures
Breaker/Fuses
IEC Style
Starter
NEMA Style
Starter
Contactor
Freedom C306
Overload
• Thermal
• 0.25 - 1500A
Relay
XT
• Thermal
•0.1 - 630A
• OLR relay opens up
contactor and prevents
motor insulation breakdown
• Technology used – Thermal
expansion properties of bimetal cause trip
Motor
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Bi-Metal Technology Overview
•
User selects “Heater Packs” by
motor nameplate FLA (Full
Load Amps)
• User selects singular overload
trip class (either 20,10 by
purchasing specific heater pack
Drawbacks
• Very limited adjustability of FLA
range 1.6:1 – Why?
•
•
Thermal properties of metal
Inconsistencies in trip times –
Why?
•
•
10-15% variation in trip times
Manufacturing of metal
compositions
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Solid-State Technology Overview
Benefits:
C440
• Electronic
• 0.3 - 1500A
• Communicating
• Ground Fault
C441 Motor Insight
• Energy Monitoring
• Motor and Pump Protection
• Advanced Diagnostics
• 1 - 540A
•
No “Heater Packs”
•
Settable Trip Class (5,10,20,30)
•
Very wide adjustability of FLA
range – Why?
•
Flexibility of electronic design
•
Large reduction of part
numbers
•
More motor protection onboard
•
More consistent protection
•
Energy cost avoidance
•
Pump and Load Protection
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C440 Protects & Monitors Motors w/ Fewer Part #’s
0.33
1.65
1
5
4
20
9
• 5 part numbers (excluding
CTs) for 0.33-1500 amps!
45
20
100
35
175
• 0-690 Vac
60
300
CT Ranges
120
600
200
1000
300
1500
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6
C441 Protects & Monitors Motors w/ Fewer Part #’s
1
9
5
90
• Motor coverage from 1-540
amps with only 2 part numbers
FLA Ranges w/CTs
60
• 0-660 Vac
135
120
270
240
540
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Comparison to the Equivalent Bi-Metal Relays
Which has more capability?
210 Thermal Overload Relays
or
5 Eaton Electronic Overload Relays
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8
Training Goals
• Understanding of basic motor protection then and now
• “5 Ways to Protect Your Motor”
• Leveraging additional capabilities from electronic relays
beyond simple thermal protection to protect motors
• “Protecting your Utility bill”
• Getting onboard the energy monitoring trend with today's
relays
• “Protecting your load/pump”
• Seeing beyond the motor to the actual load with no additional
hardware
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9
C440 and C441 Overload Relay Value
•
Advanced warning/protection and location of a pending motor/load failure
•
Improves process uptime and throughput
•
Reduces costs per repair
•
Reduces capital expenditures through extension of life
•
Optimizes labor- “Finding the needle in the haystack” (which motors get serviced during shutdown)
Sensorless, non-intrusive, starter-based technology (you need one anyway!)
•
Cost-effective (versus sensors, wiring, man-hours for install and data interpretation)
•
Greater motor coverage
•
No firewall to penetrate, since there is no data interpretation needed
catastrophic
Protection
Degree of/#
of failures
•
Accurate
Diagnostics
decreases length
of downtime and
repeat faults
$
decreases
maintenance
cost per repair
and extended
downtime
$
minor
Monitoring =
Scheduled
Downtime &
Energy Cost
Avoidance
time
Advanced warning and minor
repair extends equipment life
and reduces capital
expenditure
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10
Solid State vs Bi-Metal OL:
Thermal & GF Protection
Protection Feature
Bi-Metal Overload
Eaton’s C440 and C441
1. Thermal Overload
• Not very accurate
• Accurate, Reliable – electronic design
• Relies on thermal characteristics of metals
• Microprocessor based trip time calculations
utilize thermal memory tables
• Different heater elements for Class 10 or
20
2. Ground Fault
• Does not protect against ground fault
• Selectable trip classes (5 - 30)
• Integral design – no external CT or module
• Selectable (ON/OFF)
2. Ground Fault
• Definition:
•
•
A line to ground leakage path from the motor to the ground
Result:
•
An undetected Ground Fault can burn through multiple insulation
windings ultimately leading to motor failure
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Solid State vs Thermal
OL: Phase Protection
Protection Feature
Bi-Metal Overload
Eaton’s C440 and C441
3. Phase Loss
• Does not protect against phase loss
• Programmable Phase Loss and Phase
Imbalance
4. Phase Unbalance
(current)
• Does not protect against phase unbalance
• Takes starter off-line in 1-20 seconds
• Eaton’s C306 bi-metal provides protection
against phase unbalance, but may take up to 2
hrs.
• Selectable (ON/OFF)
3. Phase Loss - Current (single-phasing)
•
Definition:
•
•
Source:
•
•
One of the three phase voltages is not present
Loose wire, improper wiring, grounded phase,
open fuse, etc.
Result:
•
•
Single-phasing can lead to unwanted motor
vibrations causing mechanical wear
Reducing the life of your motor from the extra
heat on the other two phases
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12
Solid State vs Thermal
OL: Jam/Stall/Overcurrent
Protection
Feature
Bi-Metal Overload
Eaton’s C441
5. Jam/Stall
• Does not provide Jam Protection
6. Overcurrent &
current level alarming
• Does not provide Overcurrent
• Programmable Jam and Stall Protection
from 100%-400% of FLA
•Same setting can be used down to 50%
of FLA for current alarming
5. Jam
•
Definition:
•
•
Source:
•
•
Jam is a current draw on the motor above normal operating conditions,
often referred to as locked rotor current. During initial start-up this is
referred to as Stall.
Mechanical stall, interference, jam, or seizure of the motor or motor load
Result:
•
•
To drive the additional load the motor draws an abnormal amount of
current, which can lead to insulation breakdown and motor failure
Mechanical failure of devices that are jammed caused by the extra torque
of the motor.
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13
Solid State vs Thermal
OL: Phase Reversal
Protection
Feature
Bi-Metal Overload
Eaton’s C441
7. Phase Reversal
• Does not protect against reversal of phase
• Programmable Phase Reversal
Protection
•ABC, ACB or OFF
7. Phase Rotation (phase-reversal)
•
Definition:
•
•
Source:
•
•
•
Improper wiring leading to phases being connected to the motor
improperly causing the motor and load to spin the wrong direction
A mis-wired motor
Inadvertent phase-reversal by the utility
Result:
•
•
•
Phase-reversal can cause unwanted directional rotation of a motor
Possible mechanical failure and/or injury to an operator
You wouldn’t drive your car and then throw it in reverse at 60 mph
would you?
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Solid State vs Thermal OL:
Line Quality Protection
Protection
Feature
Bi-Metal Overload
Eaton’s C441
8. Under Voltage
• Does not protect against under or over voltage
9. Over Voltage
• Does not protect against voltage at all
• Fully programmable over and under
voltage protection
• Alarm and Trip modes
• Auto resets when voltage is good
Under voltage
•
Definition:
•
•
Source:
•
•
When the line voltage to the motor is below the specified rating
Poor line quality
Result:
•
•
•
•
motor stall
spinning the motor too slowly which effects throughput
excessive current draw. This increases the heating of the motor
windings and can shorten insulation life.
A trip limit set to 90% of rated voltage is recommended by NEMA.
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Training Goals
• Understanding of basic motor protection then and now
• “5 Ways to Protect Your Motor”
• Leveraging additional capabilities from electronic relays
beyond simple thermal protection to protect motors
• “Protecting your Utility bill”
• Getting onboard the energy monitoring trend with today's
relays
• “Protecting your load/pump”
• Seeing beyond the motor to the actual load with no additional
hardware
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16
Energy Monitoring
• Customers could realize an estimated $23B savings (U.S.)
Revenue Impact ($$)
Annual U.S. Savings Potential from Continuous
M onitoring for Energy Efficiency and Reliability
$7,000,000,000
$6,000,000,000
Energy Cost Savings ($$)
Maintenance Cost Savings ($$)
$6.2B
$6.1B
$5B
$5,000,000,000
$3.6B
$4,000,000,000
$3,000,000,000
$2.3B
$2,000,000,000
$1,000,000,000
$Pump
Compressor
HVAC (Fans
and
Refrigeration)
Conveyor
Other (material
processing,
….)
Sources: DOE 2002 Industrial Electric Motor Systems Market Opportunity
Assessment, US Dept of Commerce 2002 Census, Team analysis
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17
Energy Savings
• In the U.S. motors use 71% of
the electrical energy in a
typical industrial facility
Motor System Energy Use (GWh/YR)
70,000.00
60,000.00
• Large population of motors in
the 20-300 hp range
consuming the majority of
energy
50,000.00
Compressor
40,000.00
Pump
30,000.00
Fan
20,000.00
10,000.00
1-5
6-20
21-50
51-100
101-200
201-500
501-1000
1000+
• Very little monitoring done on
low horsepower motors <1%
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18
C441 Motor Insight Monitors Power
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
•Avoid peak demand charges
•
Power Factor
•Shed non-vital loads
•
Frequency*
•
Motor Run Hours*
•Identify and rectify increased consumption
•
Thermal Capacity
•Identify discrepancy between equal loads
•Identify Power Factor line Items
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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 power due to a foreign object on the
impeller
Motor Insight - Value Add:
ENERGY SAVINGS
•
•
Observed this abnormal operation
in real-time
Sent maintenance personnel
immediately upon observation and
removed the foreign object
Motor 1
Motor 2
Motor 3
50 KW
50 KW
75 KW
25 KW *12 hours * 365 days *$0.10/kw-hr= $10,655 of wasted energy
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Monitoring Beyond Energy
C440/XTOE
C441 Motor Insight
• Current per phase &
• Current Per Phase &
• Average 3-Phase RMS
• Average 3-Phase RMS
• Current Unbalance percent
• Current Unbalance Percent
• GF current
• GF current
• Thermal Capacity
• Thermal Capacity
• Motor state status
• Motor State Status
• Last fault
• Last 10faults
• Frequency
• Frequency
• Voltage Per Phase and
Average RMS
• Voltage Unbalance Percent
• Power
• Power Factor
• Motor Run Hours
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• Motor Starts Count
21
C440 and C441 Overload Relay Value
•
Advanced warning/protection and location of a pending motor/load failure
•
Improves process uptime and throughput
•
Reduces costs per repair
•
Reduces capital expenditures through extension of life
•
Optimizes labor- “Finding the needle in the haystack” (which motors get serviced during shutdown)
Sensorless, non-intrusive, starter-based technology (you need one anyway!)
•
Cost-effective (versus sensors, wiring, man-hours for install and data interpretation)
•
Greater motor coverage
•
No firewall to penetrate, since there is no data interpretation needed
catastrophic
Protection
Degree of/#
of failures
•
Accurate
Diagnostics
decreases length
of downtime and
repeat faults
$
decreases
maintenance
cost per repair
and extended
downtime
$
minor
Monitoring =
Scheduled
Downtime
Energy Cost
Avoidance
time
Advanced warning and minor
repair extends equipment life
and reduces capital
expenditure
22
22
Monitoring Data for Action
•
Modbus, DevicNet, Profibus easily ties OLRs into Plant Management
Systems
•
Schedule Maintenance when changes are detected before downtime
occurs
•
Line Quality, Pump behavior, Thermal Capacity, Consumption
•
Find the needle in the haystack and change routine spot checks into
targeted maintenance
•
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Monitoring Benefit – Doing More with Less
Cleveland Based Steel Manufacturer
Scenario
•
3 Hot Well Pumps (480VAC 150HP), two of them are needed to run all of time
and the other is hot spare.
•
3 Cold Well Pumps (480VAC 300HP), two of them are needed to run all of time
and the other is hot spare.
•
2 Panel Pumps (480VAC 300HP), one of them is needed to run all of time and
the other is hot spare.
•
2 Lance Pumps (480VAC 150HP), one of them is needed to run all of time and
the other is hot spare.
•
“We put Motor insight on each pump. We have designed a screen that
shows each motor data live. We can check the pump operation from
any PC in plant. I can also use eworkplace from home and check the
status of each pump from my couch. We trend all data collected, and
have a goal of using this to detect/predict motor failure. With all this
data, we can also automatically switch over to the spare before or
immediately after a failure. With the hot and cold well pumps, we have
to have the same number of pumps running at the same time or there
is an immediate flood in the basement.”
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Training Goals
• Understanding of basic motor protection then and now
• “5 Ways to Protect Your Motor”
• Leveraging additional capabilities from electronic relays
beyond simple thermal protection to protect motors
• “Protecting your Utility bill”
• Getting onboard the energy monitoring trend with today's
relays
• “Protecting your load/pump”
• Seeing beyond the motor to the actual load with no
additional hardware
25
25
Critical Pumps at Various Horsepower
Source: Eaton Survey in Motor Diagnostics and Motor
Health News
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26
Power-based Overload Relays can “See”
the Load beyond the Motor
Breaker/Fuses
• C441 MI looks at 3 phase current and
3 phase voltage & calculates power
• kW based OLR allows for monitoring
of load performance
Contactor
• kW based OLR allows for protection of
harmful conditions to loads (pumps)
Overload
Relay
Motor
Load
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27
Load Protection
Protection
Feature
Bi-Metal Overload
Eaton’s C441
10. Low Power
• Does not protect against under or over
voltage
• Fully programmable over and under
voltage protection
• Does not protect against voltage at all
• Alarm and Trip modes
11. High Power
• Auto resets when voltage is good
Low Power
•
Definition:
•
•
Source:
•
•
Power provided to the motor falls below normal operating conditions
A portion of the user's load disappears, changed in viscosity, hydraulic fluid leakage,
reduction in feed-rate, 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 breaking down desired fluid properties
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28
C441 Pump Protection
•
Open valve = not dead-headed
•
Good pump state, because the fluid in
the centrifugal pump is constantly
flowing keeping the pump cool
•
Outlet
Valve
In this state Motor Insight would read
nominal power (KW) draw
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How Motor Insight Protects a Low Suction
Head/Starved Centrifugal Pump
A low suction head
situation creates a low
power draw on the
motor. Motor Insight
detects the low power
draw and trips the motor
to protect the pump
•
Closed inlet valve = Low
suction head or dry pump.
•
This can be caused by a
closed valve as shown here,
or a unnatural clog from
foreign material
Outlet
Valve
Inlet
Valve
30
30
C441 Motor Insight Protects a
Dead-headed Pump
•
Closed blocked
valve/dead-headed =
bad pump state
Outlet
Valve
A dead-head situation creates a low power draw
on the motor. Motor Insight detects the low
power draw and trips the motor to protect the
pump saving your seals, downtime and
maintenance costs
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What did we learn?
•
More than “5 ways” to protect your motor and process
•
•
Advanced Motor Protection
•
•
•
•
•
Avoid unnecessary energy costs
Shed non-vital loads
Identify and rectify increased consumption overtime
Identify discrepancy between equal loads
Identify Power Factor Line Items
Other Benefits of Monitoring
•
•
Improves process uptime and throughput
Reduces costs per repair
Reduces capital expenditures through extension of life
Optimizes labor- “Finding the needle in the haystack” (which motors get serviced during shutdown)
“Protecting your Utility bill”
•
•
•
•
•
•
Thermal, GF, Phase loss, Phase Imbalance, Jam, Stall, Current level alarms, Phase Reversal, Under
Voltage, Over Voltage, etc.
Early detection of failures
“Protecting your load/pump”
•
•
•
•
•
•
Pump failures from deadhead and dry conditions
Submersible pump/motor failure from poor line conditions
Detect improper feed-rates
Detect improper viscosities
Find broken shafts/belts
Leakage of hydraulic lines
32
32
Motor Protection Relay Value Map to Process
Uptime, Energy Savings, & Diagnostics
Performance
2010
2009
Motor Insight
• Energy Monitoring
• Motor and Pump Protection
• Advanced Diagnostics
• 1 - 540A
2010
C440
2010
Current product GAP,
Electronic Overload
C440
with Ground Fault
• Electronic
and
• 0.3 - Communications
1500A
• Electronic
• 0.3 - 1500A
• Communicating
• Ground Fault
2010
XT SmartWire
•Communicating
• 0.3 - 65A
2011
XT
• Thermal
•0.1 - 630A
Freedom
C306
XT PKE
• Thermal
• 0.25 - 1500A
•Electronic
• 0.3 - 65A
XT XTPR
•Thermal
• 0.1 - 65A
Price
33
33
“5 Ways to Protect your Motor and Increase your
Uptime with Solid-State Overload Relays”
hosted by Erie Bearings
Adam Krug – Product Manager
Industrial Controls Division, Eaton Corporation
Thanks for Participating in the Webinar!
© 2008 Eaton Corporation. All rights reserved.
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