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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.

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Presentation on theme: "“5 Ways to Protect your Motor and Increase your Uptime with Solid-State Overload Relays” -hosted by Erie Bearings Adam Krug – Product Manager Industrial."— Presentation transcript:

1 “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

2 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 S601 Native Modbus comms vs QC port 120VAC vs 24VDC control power Accepts standard (commodity) lugs re Burndy, Ilsco etc Replaceable control board, power poles & contactor Use standard DP contactors S801/S811 used Freedom bypass contactor Larger footprint than S801/S811 Enclosed control/MCC versions Motor Insight type removable keypad Don’t print for handouts.

3 Traditional Motor Protection Overview
Traditional OLR’s monitor 3-phase current to simulate motor winding temperatures OLR relay opens up contactor and prevents motor insulation breakdown Technology used – Thermal expansion properties of bi-metal cause trip Breaker/Fuses IEC Style Starter NEMA Style Starter Contactor Freedom C306 Thermal A Overload Relay Motor XT Thermal A

4 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

5 Solid-State Technology Overview
Benefits: 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 C440 Electronic A Communicating Ground Fault C441 Motor Insight Energy Monitoring Motor and Pump Protection Advanced Diagnostics A

6 C440 Protects & Monitors Motors w/ Fewer Part #’s
5 part numbers (excluding CTs) for amps! 0-690 Vac Q1 2011 CT Ranges

7 C441 Protects & Monitors Motors w/ Fewer Part #’s
Motor coverage from amps with only 2 part numbers 0-660 Vac FLA Ranges w/CTs

8 Comparison to the Equivalent Bi-Metal Relays
Which has more capability? 210 Thermal Overload Relays or 5 Eaton Electronic Overload Relays

9 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 S601 Native Modbus comms vs QC port 120VAC vs 24VDC control power Accepts standard (commodity) lugs re Burndy, Ilsco etc Replaceable control board, power poles & contactor Use standard DP contactors S801/S811 used Freedom bypass contactor Larger footprint than S801/S811 Enclosed control/MCC versions Motor Insight type removable keypad Don’t print for handouts.

10 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 decreases maintenance cost per repair and extended downtime Accurate Diagnostics decreases length of downtime and repeat faults $ Degree of/# of failures $ minor time Advanced warning and minor repair extends equipment life and reduces capital expenditure Monitoring = Scheduled Downtime & Energy Cost Avoidance

11 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 Relies on thermal characteristics of metals Different heater elements for Class 10 or 20 Accurate, Reliable – electronic design Microprocessor based trip time calculations utilize thermal memory tables Selectable trip classes (5 - 30) 2. Ground Fault Does not protect against ground fault 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 S601 Native Modbus comms vs QC port 120VAC vs 24VDC control power Accepts standard (commodity) lugs re Burndy, Ilsco etc Replaceable control board, power poles & contactor Use standard DP contactors S801/S811 used Freedom bypass contactor Larger footprint than S801/S811 Enclosed control/MCC versions Motor Insight type removable keypad Don’t print for handouts.

12 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 Takes starter off-line in 1-20 seconds Selectable (ON/OFF) 4. Phase Unbalance (current) Does not protect against phase unbalance Eaton’s C306 bi-metal provides protection against phase unbalance, but may take up to 2 hrs. 3. Phase Loss - Current (single-phasing) Definition: One of the three phase voltages is not present Source: 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 S601 Native Modbus comms vs QC port 120VAC vs 24VDC control power Accepts standard (commodity) lugs re Burndy, Ilsco etc Replaceable control board, power poles & contactor Use standard DP contactors S801/S811 used Freedom bypass contactor Larger footprint than S801/S811 Enclosed control/MCC versions Motor Insight type removable keypad Don’t print for handouts.

13 Solid State vs Thermal OL: Jam/Stall/Overcurrent
Protection Feature Bi-Metal Overload Eaton’s C441 5. Jam/Stall Does not provide Jam Protection Programmable Jam and Stall Protection from 100%-400% of FLA Same setting can be used down to 50% of FLA for current alarming 6. Overcurrent & current level alarming Does not provide Overcurrent 5. Jam Definition: 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. Source: 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. Moving on, the next Motor Protection setting that Motor Insight provides is “Jam.” Jam is similar to Thermal overload in that it is current draw on a motor above normal operating conditions. It is typically more of a spike in motor current as opposed to a slow increase in current over time. The spike is typically caused by a mechanical stall, interference, jam, or seizure of the motor or motor load. If a Jam occurs and goes undetected the result is insulation breakdown. One might question why can’t thermal overload detect the high spikes of current? Well it can, and will, however CSA, UL, and IEC dictate the tripping behavior and trip times of thermal overload. Jam is settable by the user allowing for customizable protection. Motor Insight has Jam protection that is settable between 150 and 400% of FLA. The user can set a trip delay from 1-20 seconds to avoid any nuisance tripping. This programmability allows the user to dictate the right amount of protection for their system, before any motor failure occurs. One thing to point out is that Jam is only operational during “Motor Run State,” which means you will not get any nuisance tripping during start-up, when current spikes normally occur. If for some very odd reason you do, Motor Insight is equipped with a “start-cycle configuration,” which is the solution for strange starting and slow starting loads. For more on this, please consult the manual.

14 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: Improper wiring leading to phases being connected to the motor improperly causing the motor and load to spin the wrong direction Source: 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? The last of motor Insight’s Motor Protection is “Phase Rotation.” Phase rotation occurs when the phases to the motor are connected improperly. This can be caused by mis-wiring or an inadvertent phase-reversal by the utility. If phase-reversal goes undetected it can lead to unwanted directional rotation of a motor and associated loads. This can have severe consequences such as catastrophic mechanical failure and/or injury to an operator. Motor Insight’s “Phase Rotation” protection setting allows the user to define the phase sequence intended for their application. The wiring scheme can be set as ABC, ACB, or set to off to ignore the wiring sequence.

15 Solid State vs Thermal OL: Line Quality Protection
Protection Feature Bi-Metal Overload Eaton’s C441 8. Under Voltage 9. Over Voltage Does not protect against under or 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: When the line voltage to the motor is below the specified rating Source: 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. The next type of Line protection that Motor Insight provides is that of Under Voltage. This type of fault occurs when the line voltage to the motor falls below the rated voltage for the motor. This is typically caused by poor line quality. If the Under Voltage goes undetected it can cause excessive current draw, increasing the heating of the motor windings and shortening insulation life. NEMA recommends a trip limit set to 90% of the rated voltage. Motor Insight has a programmable under voltage protection setting. All line related faults are by default set into an “alarm-no-trip” mode, but additionally can be setup to trip. Motor Insight provides three phase voltage monitoring both locally and through communications.

16 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 S601 Native Modbus comms vs QC port 120VAC vs 24VDC control power Accepts standard (commodity) lugs re Burndy, Ilsco etc Replaceable control board, power poles & contactor Use standard DP contactors S801/S811 used Freedom bypass contactor Larger footprint than S801/S811 Enclosed control/MCC versions Motor Insight type removable keypad Don’t print for handouts.

17 Energy Monitoring Customers could realize an estimated $23B savings (U.S.) $6.2B $6.1B $5B $3.6B $2.3B Sources: DOE Industrial Electric Motor Systems Market Opportunity Assessment, US Dept of Commerce 2002 Census, Team analysis

18 Energy Savings In the U.S. motors use 71% of the electrical energy in a typical industrial facility Large population of motors in the hp range consuming the majority of energy Very little monitoring done on low horsepower motors <1% Motor System Energy Use (GWh/YR) - 10,000.00 20,000.00 30,000.00 40,000.00 50,000.00 60,000.00 70,000.00 1-5 6-20 21-50 51-100 1000+ Compressor Pump Fan

19 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 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 Power Factor line Items

20 25 KW *12 hours * 365 days *$0.10/kw-hr= $10,655 of wasted energy
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 50 KW Motor 2 Motor 3 75 KW Key Points: Great success story showing the real value of Motor Insight (MI) Customer previously only monitoring flow to detect issues Flow was the same on all 3 pumps but MI observed 1 of the pumps had abnormally high current – ended up being foreign object wrapped around the impeller Savings of over $12,000 in energy per year The customer use-case we will discuss in all three examples is a WWTP in Sheboygan, Wisconsin. This case study was the result of a 19 user, 21 application beta study performed prior to the Motor Insight launch. This success story is available at (Document # CS E), as well as in the May 2009 edition of Control Engineering. The first way that Motor Insight added value to Sheboygan WWTP was through real-time monitoring that led to energy savings. Sheboygan had three 75 hp motors with a tripping current of 96 amps. They were using Size 3 bi-metallic overload relays to protect the motors. They were also using three flow meters on the output side of each pump to ensure that the process was fully functional. They were bringing the flow data back to their headquarters and their SCADA system, however with bi-metallic overload relays, they had no means of monitoring anything else. Soon after they installed three Motor Insight’s in place of the size 3 overloads, they noticed something peculiar. While all three pumps had the same flow reading on the flow meter, one of the three motors was drawing 90 amps, while the other two were drawing 60 amps. Since all three motors and pumps were sized the same, they found this very strange. They sent a service technician to the third pump and found a foreign object wrapped around the impeller. Once the foreign object was removed, they found that the current draw went back down to 60 amps. So what does this mean? Well, in this instance the deviation to 90 amps was not enough to trip the bi-metal or the Motor Insight overload relay, as 90 amps was not above the rated tripping current for the motor. However, this additional amperage draw results in large energy losses if it goes undetected. Motor Insight’s advanced monitoring and communications allowed the plant to observe this behavior in real-time. They were able to rectify the situation, which saved them ~ $12,579 in energy costs. Not to mention the extra mechanical and electrical stress on the pump and the motor caused by the foreign object. As you can see, even small deviations in performance left undetected can be very detrimental to an operation. In this instance it was an instantaneous event that was observed. Looking at a longer timeline, as your bearings and bushings wear, you can use the monitoring data to observe your motor running hotter due to the additional friction. This can help the user decide when to replace motors and pumps. 25 KW *12 hours * 365 days *$0.10/kw-hr= $10,655 of wasted energy

21 Monitoring Beyond Energy
C440/XTOE Current per phase & Average 3-Phase RMS Current Unbalance percent GF current Thermal Capacity Motor state status Last fault Frequency C441 Motor Insight Current Per Phase & Average 3-Phase RMS Current Unbalance Percent GF current Thermal Capacity Motor State Status Last 10faults Frequency Voltage Per Phase and Average RMS Voltage Unbalance Percent Power Power Factor Motor Run Hours Motor Starts Count

22 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 decreases maintenance cost per repair and extended downtime Accurate Diagnostics decreases length of downtime and repeat faults $ Degree of/# of failures $ minor Monitoring = Scheduled Downtime Energy Cost Avoidance time Advanced warning and minor repair extends equipment life and reduces capital expenditure

23 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

24 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.” Key Points: Prior they required weekly inspections with 2 people MI eliminated unnecessary inspections, optimized labor skill sets and reduced service time all saving over $7000 per year As the key point in the last example was Energy Savings, here we will talk about Maintenance Optimization, or “doing more with less,” as I hear it referred to quite often. In follow-up interviews with the Plant Manager and Engineering Manager we discovered that Motor Insight allowed the facility to change their maintenance practices. Prior to the use of Motor Insight, the lack of data available from the remote lift stations required the plant to send 2 maintenance personnel once a week to inspect the pumps and motors (50 times a yr). The pumps are typically 30 ft below ground, so OSHA requires a top-man to be present while someone proceeds into the confined space. The inspector did not use any sophisticated means of performing the inspection and it consisted of little more than listening to operating noise, and feeling for vibration. As they went out to each site, the inspectors would have no pre-notion of any problems that might be occurring, so their was no guarantee that they were qualified to handle the job, or that they had the right tools with them. If a problem was discovered it was sometimes necessary to make a trip back to the headquarters building to grab the right tools and the right person for the job, adding time to the service call. Since installing the Motor Insight’s, Sheboygan was able to change their maintenance practices. The real time data monitoring along with the 10 fault history allows the headquarters to only send personnel when Motor Insight reports an issue eliminating unnecessary inspections. Sheboygan also used the available data provided by Motor Insight to reduce the service time for any repair. Understanding the fault-type, allows the end-user to find the smoking gun quickly. Without using Motor Insight a lot of faults will look like high current, but Motor Insight can point out exactly what caused the condition, whether it was caused by the line voltage, load behavior, or a motor fault. Knowing the cause of the fault reduces the diagnostic time. Additionally, by having that information available remotely allows the plant to send the right person and the right tools for the job, avoiding return trips to the plant. Which bring us to the last point. Sheboygan stated the Motor Insight helps them to optimize their labor skill set, reducing the overall costs of repairs. The information provided by Motor Insight provides them with knowledge of what exactly occurred, so they can avoid sending their 40 year veteran to clear a rag out of an impeller. They can better utilize him elsewhere in the plant. For just this one lift station, we estimated that the Motor Insight saves them approximately $7100 in maintenance costs a year. This comes from eliminating unnecessary inspections, reducing the service time per repair, and reducing overall labor costs by optimizing skill sets. Multiply this savings by the number of lift stations in a given city and you have some significant savings.

25 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 S601 Native Modbus comms vs QC port 120VAC vs 24VDC control power Accepts standard (commodity) lugs re Burndy, Ilsco etc Replaceable control board, power poles & contactor Use standard DP contactors S801/S811 used Freedom bypass contactor Larger footprint than S801/S811 Enclosed control/MCC versions Motor Insight type removable keypad Don’t print for handouts.

26 Critical Pumps at Various Horsepower
Source: Eaton Survey in Motor Diagnostics and Motor Health News

27 Power-based Overload Relays can “See” the Load beyond the Motor
C441 MI looks at 3 phase current and 3 phase voltage & calculates power kW based OLR allows for monitoring of load performance kW based OLR allows for protection of harmful conditions to loads (pumps) Breaker/Fuses Contactor Overload Relay Motor Load

28 Load Protection Low Power Definition: Source: Result:
Protection Feature Bi-Metal Overload Eaton’s C441 10. Low Power 11. High Power Does not protect against under or 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 Low Power Definition: Power provided to the motor falls below normal operating conditions Source: 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 That wraps up the discussion on Motor faults and Motor protection. We will now move onto what we refer to as Load Protection. As discussed in the introductory slides, Motor Insight is an advanced overload relay, different from traditional solid-state overloads because it not only measures current but also voltage. With both voltage and current measurements, Motor Insight can calculate the power going to the motor. When thinking about the different types of protection it is helpful to think of this: Motor Protection is based on Current, Load Protection is based on Power, and Line Protection is based on Voltage. So what is meant by Load Protection? Load protection refers to the fact that the Motor Insight can actually infer as to what is changing at your load (pump, conveyor, rake, etc), and offer a greater degree of protection. One of the first methods of performing load protection was by using “under-current” protection. Today it is more preferable to use “under-power” protection. I just finished saying that Load Protection is based off of the changes to Power, so why would I mention under-current? The answer is that prior to the development of advanced overloads, a rudimentary form of load protection was done by providing a fault when an “under current” occurred. Remember the first types of overloads we discussed were only able to sense current. When a portion of a user’s load disappears, due to a broken belt, a dry-pump (low suction head), or a dead-headed centrifugal pump, there is less mechanical resistance to the motor, and so the current draw to the motor also drops. By setting a threshold for under current the user was able to crudely detect that something happened to their load. Motor Insight does have an “under current “ protection setting available, however the more reliable means of protecting your load is by utilizing “under power.” Under power is superior for two reasons. First off, fluctuations in your line voltage can lead to current drops. If voltage goes high, current drops, thus if you were using under current protection you may get a trip that was triggered by the poor line condition which had nothing to do with what was actually happening at your load. The user’s process is now down. Down time is lost productivity and revenue, not to mention possible fines if you are talking water or wastewater. Therefore the under current setting took the process down and offered no protection to the load, as the load was not in a harmful condition. The second reason that Under Power is superior to Under Current for protecting loads is due to the linear relationship of Power with Load vs. the non-linear relationship of Current with Load. There are more details of this covered in the competitive comparison, but essentially what this means is that Power provides the same level of sensitivity for protection regardless of where the user is operating on their load curve (Lightly loaded or Heavily Loaded), whereas due to the non-linear nature of current with load, the user has very sensitive protection when the device is heavily loaded, which can cause nuisance trips leading to downtime. On the other end of the spectrum under current provides very insensitive protection, when your pump is lightly loaded. This can cause the pump to burn up due to excessive heat, when the under-current protection does not sense the change in load caused by a dead-head or low-suction head. To avoid this type of nuisance trip (heavily loaded, and line fluctuations) or non-trip (lightly loaded), a user should use Motor Insight’s “under power” setting. By using power and not current, the user has a more reliable means of understanding what is truly happening at their load. Even with line fluctuations, the power measurement will remain reliable as it is a product of Voltage and Current, so line fluctuations do not affect the power readings. Therefore you will only get an under power trip condition when something is changing at your load. Therefore, anytime you think of load protection, you should think of power protection. In the case of a dead-head condition of a centrifugal pump, a dry-pump, or a broken belt, you will always get an under power trip at the same level of sensitivity throughout the load profile. This can protect your pump from excessive heating, which can damage expensive seals. Also, by taking a pump off-line when it is dead-headed you are saving energy as the pump is doing no real work. By running it when you are doing no real work, you are putting unneeded hours on bearings and bushings of the motor and pump. Therefore by using under power protection you can extend equipment life.

29 C441 Pump Protection Outlet Valve Open valve = not dead-headed
Good pump state, because the fluid in the centrifugal pump is constantly flowing keeping the pump cool In this state Motor Insight would read nominal power (KW) draw Outlet Valve

30 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 Inlet Valve Outlet Valve 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

31 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

32 What did we learn? More than “5 ways” to protect your motor and process Thermal, GF, Phase loss, Phase Imbalance, Jam, Stall, Current level alarms, Phase Reversal, Under Voltage, Over Voltage, etc. Advanced Motor Protection 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” 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 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 S601 Native Modbus comms vs QC port 120VAC vs 24VDC control power Accepts standard (commodity) lugs re Burndy, Ilsco etc Replaceable control board, power poles & contactor Use standard DP contactors S801/S811 used Freedom bypass contactor Larger footprint than S801/S811 Enclosed control/MCC versions Motor Insight type removable keypad Don’t print for handouts.

33 Manual Motor Protectors
Motor Protection Relay Value Map to Process Uptime, Energy Savings, & Diagnostics Performance Price Current product GAP, Electronic Overload with Ground Fault and Communications Overload Relays XT Thermal A XT XTPR A XT PKE Electronic A 2011 Motor Insight Energy Monitoring Motor and Pump Protection Advanced Diagnostics A 2010 Manual Motor Protectors C440 A Communicating Ground Fault Freedom C306 A 2009 XT SmartWire Communicating A 2010 Discussion points: Open (Std version) vs Assembly Play (Advanced) Does this make sense?

34 Thanks for Participating in the Webinar!
“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!

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