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ABB MACHsense-R, Instruction Manual

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Instruction manual for MACHsense-R - MSR1600

1MZB100400

A

2(31)

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties
without express authority is strictly forbidden.

© Copyright 2017 ABB

PROPRIETARY AND SECRET INFORMATION

Contents

1

Introduction

 ....................................... 4

1.1

General information

 ........................ 4

1.2

Standards

......................................... 4

1.3

Important note

 ................................. 4

1.4

Limitation of liability

 ........................ 5

2

Recycling and scrapping

 ................ 6

3

Safety Instructions

 ........................... 8

3.1

Safety precautions

 .......................... 8

3.2

General safety during MACHsense-

R installation

 ................................................ 8

3.3

Electrical 

safety 

during

MACHsense-R installation

 ........................ 8

4

Important instructions

 ..................... 9

4.1

USA & Canada compliance

 .......... 9

4.2

Europe compliance

 ....................... 11

5

Get started

 ....................................... 12

5.1

Quick 

summary 

of

the

MACHsense-R

 .......................................... 12

5.2

The  requirements  for  the  use  of

MACHsense-R

 .......................................... 12

5.3

Preparations for installation

 ........ 13

6

Installing DAU

 ................................. 14

6.1

Installation kit

................................. 14

6.2

Mounting DAU

 ............................... 15

6.3

Communications

 ........................... 16

6.4

Example of Installation

 ................. 16

7

Installation of Accelerometers

(Vibration Measurement)

 ....................... 18

7.1

Accelerometers Location

 ............. 18

7.2

Mounting of pads

 .......................... 19

7.3

Mounting of sensors

 ..................... 20

7.4

Additional information on mounting

20

7.5

Wiring  and  connection  of  sensors

20

8

Installation in Motors with Fins

.... 23

9

Installation of Magnetic Field

Sensor (MFS)

 .......................................... 24

9.1

MFS Location

 .................................24

9.2

Mounting of MFS Sensor

 .............24

9.3

Wiring  and  Connection  of  Sensor

25

10

Configuration

 .................................. 26

10.1

Preparation

 .....................................26

10.2

Commissioning

 ..............................30

11

Terms for using ABB MACHsense-

R – MSR1600 product/service

 ............. 31

Summary of Contents for MACHsense-R

Page 1: ...urity level RMMG PG Service Jan Wallden Lillemor Rapp Laxminarayan Daund Henrik Ryegard Confidential We reserve all rights in this document and in the information contained therein Reproduction use or disclosure to third parties without express authority is strictly forbidden Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION Instruction manual for ABB MACHsense R MSR1600 Reviewed by Jan Wallde...

Page 2: ...ant instructions 9 4 1 USA Canada compliance 9 4 2 Europe compliance 11 5 Get started 12 5 1 Quick summary of the MACHsense R 12 5 2 The requirements for the use of MACHsense R 12 5 3 Preparations for installation 13 6 Installing DAU 14 6 1 Installation kit 14 6 2 Mounting DAU 15 6 3 Communications 16 6 4 Example of Installation 16 7 Installation of Accelerometers Vibration Measurement 18 7 1 Acce...

Page 3: ...third parties without express authority is strictly forbidden Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION 2017 ABB Inc All rights reserved The contents of this manual are the property of ABB Inc This documentation is furnished on license and may not be reproduced in whole or in part without the permission of ABB Inc The content of this manual is for informational use only and is subject ...

Page 4: ...ten permission of ABB and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose ABB constantly strives to improve the quality of the information provided in this instruction manual and will welcome any improvement suggestions For support contact the closest ABB Local Service Centre LSC or ABB Certified Service Centre These instructions must be followed...

Page 5: ...event shall ABB be liable for direct indirect special incidental or consequential damages of any nature or kind arising from the use of this document nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document The warranty issued covers manufacturing and material defects The warranty does not cover any damage caused to the...

Page 6: ...cycling of ABB MACHsense R The equipment is designed in a way that it is easy to separate the different components and types of material from each other making it easier to recycle The methods are described in a very general way All instructions are to be performed by personnel which is trained and skilled for the procedure 2 1 2 Dismantling the equipment Risk of personal injury when dismantling t...

Page 7: ... Copper Different types of wires cables used in DAU Polycarbonate sheet Transparent sheet to shield PCB o Main Board o A C input board o PoE board Carbon Steel Not used Special high quality steel Not used Mixed metallic material Not used Electronic waste The below items should be disposed and recycled as electronic waste as per WEEE directive Cables PCB Power supply unit WiFi module GPRS module Et...

Page 8: ...intenance procedures and tests required for rotating electrical machines Please read this section before you familiarize yourself with the MACHsense R initial product setup and registration process 3 2 General safety during MACHsense R installation Handle the MACHsense R carefully and must not be dropped Use safety shoes with metal toe cap during installation to avoid foot injury Don t install or ...

Page 9: ...ce may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation FCC Caution statements 1 Any changes or modifications not expressly approved by the party Responsible for compliance could void the user s authority to operate this Equipment 2 This equipment should be installed and operated with minimum distance 2...

Page 10: ...eur à utiliser cet équipement 2 Cet équipement doit être installé et utilisé à une distance minimale de 20 cm entre le radiateur et votre corps REMARQUE Cet équipement a été testé et jugé conforme aux limites d un appareil numérique de classe A conformément à la section 8 4 de RSS Gen Ces limites sont conçues pour fournir une protection raisonnable contre les interférences nuisibles lorsque l équi...

Page 11: ...onnel must be familiar with general device test practices electrical awareness and must take proper safety precautions when installing and or servicing the equipment Before performing installation inspections tests or maintenance on this device or associated circuits all live circuits and sources of electric power to said device and circuits must be isolated or disconnected Failure to shut off equ...

Page 12: ...rammed to pick up signals relating to the motor s health and operating parameters The collected data is then transferred via GPRS to MACHsense R secure ABB designated server The data will be processed by algorithms developed by ABB and turned into meaningful information for the user to view and manage in the portal The DAU is an IP56 certified device housed in painted stainless steel casing MACHse...

Page 13: ...ts in correct installation assures safe running conditions and maximum accessibility During installation general as well as local safety instructions must be followed 5 3 2 Power supply MACHsense R requires external power supply 110 240 V AC Recommended fuse is 10 A Recommended cable area is 1 5 mm2 Installation should be made by certified electrician according to local regulations and applicable ...

Page 14: ...ense R kit contains the following Item description DAU Accelerometers four Mounting pad four Cable four 10 m each Installation guidelines The recommended way of installing vibration sensors is to glue the mounting pads into their correct position on the motor Recommended glue Loctite AA326 Recommended Activator Loctite SF7649 Recommended cleaner Loctite 7061 Note Mounting glue is not included in t...

Page 15: ... use or disclosure to third parties without express authority is strictly forbidden Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION 6 2 Mounting DAU Monitoring device can be mounted on the motor or on neighbouring wall or steel structure depending on the feasibility of the condition Drilling machine can be used for drilling mounting holes and fixing DAU using suitable bolts MACHsense R pictu...

Page 16: ...ximity to electrical appliances etc Selected mounting location and subsequent mounting of DAU should allow trouble free cabling The DAU should be mounted where it is easy accessible for service technician to connect laptop into the LAN connector inside the DAU Sufficient reserve should be provided for connectors Ensure correct fastening of mounting bolts to prevent any sudden unfastening due to ex...

Page 17: ...hority is strictly forbidden Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION The DAU can also be mounted on the same side as auxiliary terminal box to reduce the cable length for RTD BTD For non Ex applications Cable length up to 500 ft 150 m can accurately transmit data from sensors datasheet For Ex applications Cable length up to 1600 ft 480 m can accurately transmit data from sensors data...

Page 18: ... is important to locate the best positions on the motor The accelerometer is single axis and measures only in one direction Accelerometer diagram and technical specs Channel 0 Motor Drive End horizontal direction Find a position on the side of the motor This position should be pointing directly in towards the bearing Channel 1 Motor Non Drive End horizontal direction Find a position on the side of...

Page 19: ...A326 on the mounting pad Make sure you put glue on the side where the threaded mounting hole is not positioned 4 Spray some activator Loctite SF7649 on the glue and on the surface on the motor Immediately attach the pad in correct position and keep steady for 15 minutes Mounting pad diagram and technical specs LOCTITE AA 326 is a yellow to amber no mix medium viscosity thixotropic structural and m...

Page 20: ...ards the shaft centreline High frequency oscillation loses some of its energy in the face of the interface Therefore the measuring point has to be chosen in such a way that the point of measurement and the sensor have minimal interfaces Vibration of rotating equipment is transferred to the bearings through the body So the measurement points should be selected as close as possible The sensor mounti...

Page 21: ...er conduit and trays wherever required to help cables withstand the operating environment The sensor cables should be laid away from high voltage cables by distance of at least 250 mm 5 Connect the shield of the cable to the cable gland for proper ESD protection 6 Locate X54 Connector on the DAU Board Refer below Terminal Layout for reference Cable diagram and technical specs Terminal layout in DA...

Page 22: ...FORMATION 7 Ensure proper polarity while connecting the sensor to the DAU Connector Pin polarity DAU Board Connection Sensor protection and wiring must be carried out reliably and in accordance with good engineering practice The sensor must not be allowed subject to a greater acceleration or temperature The sensor location should not hinder other operational and maintenance measures Proper install...

Page 23: ...fin mount pad 3 Place the motor fin mount pad between the motor fins at the desired location a Correct motor fin mount selection is important b The probe must fit in between the motor fins and the bottom of the probe must contact the motor casing 4 Firmly press the motor fin mount pad into place ensuring the bottom of the motor fin mount pad is touching the motor casing this is the contact area wh...

Page 24: ...ly on the motor The enclosure is made from plastic material Use of Loctite 407 is recommended Procedure for gluing the enclosure 1 All paint must be removed from the surface Make sure all paint is grinded and the Sensor is glued directly on the metal on the motor 2 Apply glue Loctite 407 on the motor surface 3 Stick the plastic enclosure and put the cable to the DAU 4 After gluing the sensor the c...

Page 25: ...ensor The sensor cable has 4 connection pairs as below Vsupply 5V Com X Axis GND Y Axis GND Z Axis GND Locate Connector X54 on the DAU Board and refer following illustration for identifying the MFS Connections Terminal layout in DAU The MFS connections must be in the following order X54 B0 Ch4 Channel 4 X Axis X54 B0 Ch5 Channel 5 Y Axis X54 B0 Ch6 Channel 6 Z Axis Note the polarity while connecti...

Page 26: ...closure to third parties without express authority is strictly forbidden Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION 10 Configuration 10 1 Preparation After installation have been done the MACHsense R unit needs to be configured Make sure that the power is switched off before putting in the SIM card Only micro SIM cards can be inserted in the provided hatch PIN code of the SIM card needs...

Page 27: ...rbidden Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION 1 First step is to insert SIM card in the SIM card holder 2 Open the hatch put in SIM card in correct position and close the hatch 3 Next step is to connect a computer by using a network cable to connect between Laptop and MACHsense R RJ45 connector In order to have all necessary information make sure that the following information abou...

Page 28: ...t name MACHsense R MAC address Drivetrain name Machine name The above filled in information will be used for naming the machine in web portal Manufacturer Machine Serial Number Machine Type Motor Generator Number of rotor bars if known Connection Type Star Delta N A Starting Direct online Variable Speed Drive Rated Power kW Rated Voltage Stator V Rated Current Stator A Frequency Hz Speed at Rated ...

Page 29: ...on contained therein Reproduction use or disclosure to third parties without express authority is strictly forbidden Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION Sim card operator company Customer Contact persons Name Email Mobile Phone Number for SMS notifications Please provide photos of motor nameplate and all machine including driven object and foundation ...

Page 30: ...nt and in the information contained therein Reproduction use or disclosure to third parties without express authority is strictly forbidden Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION 10 2 Commissioning Digitally connect MACHsense R using the ABB Ability MACHsense R Android app Log on using your credentials and follow prompts to connect ...

Page 31: ...1600 product service By registering and using the MACHsense R portal you are confirming that ABB will own the collected data and that this data can be used for future product development and that you will comply with all ABB website terms and conditions of use as well as its Cookies and Privacy Policies By downloading installing activating accessing or otherwise using the MACHsense R Portal you ha...

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