Smart MCCs as a motor maintenance tool

Siemens Energy & Automation, Inc.

www.sea.siemens.com

www.sea.siemens.com/mcc

Smart Motor Control Centers December 1, 2008

This paper will discuss the application of Smart MCC technology to standard
and predictive maintenance practices used to maximize motor life and help
limit unplanned motor failure. An overview and definition of standard
maintenance practices is followed by a description of information available
from a Smart MCC and how this information can be used.

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White Paper | Smart Motor Control Center | December 1, 2008 2

Table of Contents

1. Introduction 1

2. Motor Maintenance Overview 2

2.1. Time-based Maintenance 4

2.2. Condition-based Maintenance 5

3. Siemens Smart MCC Overview 6

4. Siemens Smart MCC as a Motor Maintenance Tool 7

4.1. SIMOCODE Pro 8

4.1.1. SIMOCODE Pro Measured Data for Maintenance 9

4.1.2. SIMOCODE Pro Statistical Data for Maintenance 10

4.2.3 RW44 Soft-starter 11

4.2.1. RVSS Measurement Data for Maintenance 12

4.2.2. RVSS Statistical Data for Maintenance (Tab 1) 13

4.2.3. RVSS Statistical Data for Maintenance (Tab 2) 14

4.3. MM440 VFD 15

5. Summary 16

6. References 17

End of document 18

This document is not intended as a substitute for any product specific instruction or maintenance manual or
literature. Always consult the manufacturer‘s product specific literature prior to working on or with motors,
MCCs or related equipment.

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White Paper | Smart Motor Control Center | December 1, 2008 3

1. Introduction are reducing overall costs due to unplanned downtime and

premature motor failure.
There are significant cost benefits to having a proper motor
maintenance program in place, ranging from 10 percent to There are three possible maintenance actions that can be
14 percent reduction in energy costs, to avoiding the costs taken on every motor:
of unplanned downtime associated with a critical motor
failure (a)(b)(e). Proper application of maintenance practices • Do nothing
to eliminate chronic unplanned failure can lead to a 60% This is sometimes called the “run-until-fail” maintenance
reduction in maintenance costs, and that can mean millions of program. This may be perfectly acceptable for non-
dollars in savings. (n) critical low HP motors for items like vent fans.
• Time-based maintenance
This means that basic motor maintenance will be
completed based on how long the motor has been
in operation. This is the most common type of motor
maintenance performed on the biggest variety of motors
used in a facility. An example of this type of maintenance
would be proper greasing of the bearings and a physical
inspection.
• Condition-based maintenance
This means basic motor maintenance will be completed
based on the how long the motor has been in operation,
plus monitoring vibration or temperature of the motor.
These additional parameters can help predict failure. This
will generally need to be done on process critical
Figure 1: motors, motors that are unique, or have supply
Conditions leading to premature motor failure. chain issues. An example of this type of maintenance
would be proper greasing of the bearings plus adding
Standard maintenance programs (d)(h)(c) usually gather a vibration monitor to insure bearing is still operating
statistical data on the motor (number of starts, number of within design limits.
trips, the number of running hours) and use this data to
determine the lubrication and physical inspection interval. A quick review of the motor characteristics related to motor
For the purposes of this paper, we refer to this type of maintenance:
maintenance as “Time-based Maintenance”.

However, most motor failures can be anticipated by a few Insulation Class

physical properties of the motor in the operating condition Insulation systems are rated by standard NEMA classifications
(temperature, voltage, current, and vibration). The relative according to maximum allowable operating temperatures (d) .
levels of these variables can strongly indicate potential They are as follows:
imminent motor failure. (e)(i) The ability to anticipate
imminent motor failure through real-time monitoring Maximum Winding Winding Temperature
of physical parameters we refer to as “Condition-based Insulation Class Temperature Rise Above Ambient
Maintenance” or “Predictive Maintenance” for this paper. A 220ºF 140˚F to 160˚F
B 265ºF 175˚F to 195˚F
This paper will present an overview of electrical motor
F 310ºF 220˚F to 240˚F
maintenance, and how a Siemens Smart MCC can be used
as either a tool for “Time-based Maintenance “or “Predictive H 355ºF 255˚F to 275˚F
Maintenance” motor maintenance programs. The use of a Table A:
Smart MCC in either maintenance program will help mitigate Maximum Winding Temperature for Motor Based on Insulation Class
unplanned motor failures and avoid costly unplanned
downtime. Generally, a motor should be replaced with one having an
equal or higher insulation class. Replacing a motor with one
2. Motor Maintenance Overview of lower temperature rating could result in premature failure
of the motor. Each 10°C rise above the maximum winding
The purpose of a motor maintenance program is to extend temperature (shown in Table A) can reduce the motor’s service
the service life of the motor. The benefits to the customer life by one half.

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NEMA Electrical Design Standards It is not uncommon for the original equipment manufacturer
(OEM) to load the motor to its maximum load capability
The following table can be used to help guide which (service factor). For this reason, do not replace a motor with
polyphase design type should be selected. one of the same nameplate horsepower but with a lower
service factor. Always make certain that the replacement
Starting Breakdown motor has a maximum HP rating (rated HP x SF) equal to or
Torque Torque Starting Typical higher than that which it replaces. Multiply the horsepower by
Classification Percent Percent Current Slip Applications the service factor for determining maximum potential loading.
Design B Fans,
normal blowers, The service life rating of the motor and its use in the loading
starting centrifugal of the motor is critical to the life of the motor. Please
torque and pumps and
normal
consider the amount of voltage unbalance present, ambient
compressors;
starting 100 - 200 200 - 250 Normal < 5% where temperature, and winding temperature of motors that have
current starting been designed to run at the maximum service factor rating
torque of the motor. Consult with the motor manufacturer for the
requirements proper motor to be used as a replacement in these cases.
are relatively
low.
2.1. Time-based Maintenance
Design C Conveyors,
high starting stirring
torque and
Time-based maintenance is the completion of periodic
machines,
normal crushers, maintenance on motors based on general usage parameters,
starting agitators, like the following:
current 200 - 250 200 - 250 Normal < 5% reciprocating • Number of starts
pumps; • Total hours of running time for the motor
where
starting
• Duty cycle of the motor
under load is • Number of overload trips
required.

Design D The premise is that each motor requires lubrication and

High peak
high starting loads, loads
physical inspection based on total running time of the motor
torque and with fly- per the manufacturer instructions. (k)(l)(m)
high wheels
starting such as
current
Below is listed some general re-lubrication intervals for motors
punch press,
having grease fittings:
shears,
275 275 Normal < 5% elevators,
extractors, Hours of Service Hours of Use Before
winches, Per Year HP Range Re-lubricaton
hoists, oil
1/18 to 7 1/2 5 years
well
5000 10 to 40 3 years
pumping and
50 to 100 1 year
wire drawing
machines. to 7 1/2 2 years
Continuous Normal
10 to 40 1 year
Table B: Applications
50 to 100 9 months
NEMA Motor Design Standards
Seasonal Service -
1 year
Motor is idle for 6 All
Service Factor months or more
(beginning of season)

Continuous high
The service factor (SF) is a measure of continuous overload ambient, high vibration 1/8 to 40 6 months
capacity at which a motor can operate without overload or or where shaft end 50 to 150 3 months
damage, provided the other design parameters such as is hot
rated voltage, frequency and ambient temperature are Table C:
within the stated specifications for the motor. Motor (re)lubrication intervals

Example: a 3/4 HP motor with a 1.15 SF can operate at In addition, the number of starts, the duty cycle of the motor,
0.86 HP, (0.75 HP x 1.15 = 0.862 HP) without overheating and the number of overload trips can indicate a need for
or otherwise damaging the motor if rated voltage and increased physical inspections of the motor and the process
frequency are supplied at the motor’s leads. for changes in operating conditions.

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2.2 Condition-based Maintenance can improve the maintenance procedures used by providing
more data collected in a more continuous manner.
Condition-based maintenance, as mentioned before, relies
on detecting some physical condition of the motor and
understanding the relationship between the variable being
monitored and motor operation / motor life.
1. Each control signal 1. Control network for
The more operating conditions that can be monitored, the (start, running, etc.) control and data
has a separate wire (Reduce installation
more data can be gathered to help determine the overall and startup costs)
motor heath, leading to better diagnostics as a part of 2. No detailed power or 2. Detailed power and
condition-based maintenance. diagnostic data diagnostic data

Measure
Current, Voltage, Traditional MCC Smart MCC
Voltage Imbalance
Measure Figure 3:
Vibration
Comparison of traditional MCCs vs Smart MCCs.
cooling
air flow There are three major families of network-enabled
components delivered with the Siemens Smart MCC for
motor control:
stator fan
• Smart Overload Motor Protection (Simocode Pro C / V)
These are network-enabled devices that protect,
rotor monitor, and control the motor starter.
• Reduced Voltage Soft-starter (3RW4x)
Network-enabled device that protects and controls the
motor. During the startup of the motor, it will reduce the
non-drive voltage to bring the motor gently to its rated speed and
end voltage.
drive end • Variable frequency drive (MM4xx, 6SE70, Sinamics)
Network enable device that varies the voltage and
frequency of the output to the motor at all times to
It has been estimated that as many as 50% to control the speed of the motor.
75% of all motor failures are bearing related (fXm),
and 95% of all bearing failures are premature (m); Measure
bearing or rotor failure indication is usually Stator winding
preceded by an increase in motor vibration. (k)(l)(m) temperature 4. Siemens Smart MCC as a Motor Maintenance Tool

A Siemens Smart MCC has components that supply

Figure 2:
Measurement points for motor condition-based maintenance. increased information to support time-based and condition-
based maintenance requirements.
3. Siemens Smart MCC Overview
• SIMOCODE Pro motor management.
A “Smart” MCC is an MCC where the components have This device has the following features:
the ability to communicate on a network fieldbus back - Accepts 4-20ma and RTD inputs from external devices
to a PLC or DCS. A traditional MCC does not have these - Accepts additional inputs and outputs for motor control
communicating components installed. Through this schemes and protection
network connection, these network components collect - Program contained in device that allows it to operate
and distribute a larger amount of information than ever. with or without a master PLC / DCS controller
- Operating statistics and complete power measurement
Since these components are network-enabled and are data
designed to deliver larger amounts of information back to a - Voltage unbalance measurement
controlling PLC or DCS, it stands to reason the these devices - Operator panel

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• 3RW44 Soft- Starter (RVSS) In general:

This device has the following features:
- Operating statistics and complete power measurement Duty Cycle = time on x 100%
data time on + time off
- Line and load frequency, plus voltage unbalance
Therefore for a motor that is connected to a Simocode Pro
- Ability to accept a motor thermistor input
motor management unit:

• MM440 multi-use variable frequency drive Duty Cycle =

This device is primarily used to match the motor power [ Running time (motor) ÷ Running time (device) ]
or speed output to the process more closely than a full * 100 percent
speed motor. This load / speed matching helps reduce
maintenance and energy use at the same time. The SIMOCODE Pro provides the following information for
condition-based monitoring:
An important criteria for evaluation of a Smart MCC solution • 3 phase current, voltage
• Watts and VA
is to determine where the required information is stored.
• Power quality parameters like:
Siemens Smart MCCs have the flexibility to store relevant
- Voltage imbalance
motor data in the PLC, the motor control device, or both. - COS-PHI
This allows retention of data during PLC replacement or - Motor model heating
failure. • RTD inputs for motor winding temperature
• Analog inputs for vibration or other sensors
• Digital inputs for additional motor protection
• Digital outputs for additional signal or control devices

1. Motor data can be stored in PLC.

2. Motor data can be stored in MCC devices
3. Motor data can be stored in both locations

Choice of locations to save motor operating data

Figure 4:
Location of motor maintenance data.

4.1. SIMOCODE Pro

Standard Smart MCC overloads use the SIMOCODE Pro motor

management as the electronic overload and the motor starter
contactor controller.

The SIMOCODE Pro provides the following information for

time-based maintenance:
• Number of starts total
• Number of starts left and starts right for a reversing motor
• Total hours of running time for the motor
• Total hours of operating time for the device
• Number of overload trips
• Amount of energy (KW Hours) consumed by the motor

Please note that running time of the motor and the operating
time of the device can be used to determine the duty cycle use
of the motor.

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White Paper | Smart Motor Control Center | December 1, 2008

4.1. SIMOCODE Pro Measured Data for Maintenance

Figure 5:
Simocode Pro Maintenance Data

Condition-based maintenance: Condition-based maintenance: Condition-based maintenance:

These parameters can be used Connect optional RTDs to Connect optional vibration
to review motor winding monitor motor winding sensors to monitor motor
heating problems. temperature. operation.

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White Paper | Smart Motor Control Center | December 1, 2008

4.1.2. SIMOCODE Pro Statistical Data for Maintenance

Figure 6:
Simocode Pro Maintenance Data

Time-based maintenance:
Time-based maintenance:
Motor maintenance data used
Used to determine the motor
for service interval and
duty cycle.
periodic inspection.

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White Paper | Smart Motor Control Center | December 1, 2008

4.2 3RW44 Soft-starter

The Siemens Soft-starter offering used in the Smart MCC is a

product number 3RW44.

The 3RW44 provides the following information for time-

based maintenance:
• Number of starts left and starts right for a reversing
motor.
• Total hours of operating time for the device
• Total hours of running time for the motor, plus these
additional motor running categories useful for
calculating the duty cycle based on motor load:
- Operating hours - motor current
18 ... 49.9 percent x Ie(max)
- Operating hours - motor current
50 ... 89.9 percent x Ie(max)
- Operating hours - motor current
90 ... 119.9 percent x Ie(max)
- Operating hours - motor current
120 ... 1000 percent x Ie(max)
• Number of overload trips

Similar to the SIMOCODE Pro device the duty cycle is

calculated by:

Duty Cycle =
[ Running time (motor) ÷ Running time (device) ]
* 100 percent

The 3RW44 provides the following information for

condition-based monitoring:
• 3 phase current, voltage
• Watts
• Power quality parameters like:
- Voltage imbalance
- Contact block heating
- Motor model heating
• Thermistor inputs for motor winding temperature

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White Paper | Smart Motor Control Center | December 1, 2008

4.2. 1. RVSS Measurement Data for Maintenance

Figure 7:
RVSS Measured Real-time Data

Condition-based maintenance:
Used to determine the voltage
and current unbalance effect
on the motor windings.

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4.2.2. RVSS Statistical Data for Maintenance (Tab 1)

Figure 8:
RVSS Statistics Data (Tab 1)

Time-based maintenance:
Used to determine total duty cycle for the motor, and to
Time-based maintenance:
determine the duty cycle of the motor at 4 different load
Used to determine motor
levels. Clearly motor life will be impacted most by the duty
inspection intervals.
cycle of the motor running at greater than 120 percent of
rated load.

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4.2. 3. RVSS Statistical Data for Maintenance (Tab 2)

Figure 9:
RVSS Statistics Data (Tab 2)

Condition-based maintenance:
Maximum voltage and current determine the life of the
windings based on motor heating models.

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4.3 MM440 VFD

The MM440 VFD provides the following information for

time-based maintenance:
• Total hours of running time for the motor
• Number of overload trips

The MM440 VFD provides the following information for

conditioned-based maintenance:
• 3 phase current, voltage, and power
• Power Factor, consumed energy
• Resistance of rotor and stator windings
• Thermistor input for motor winding temperature.

Operational data for motor

performance evaluation

Drive alarms and warnings

Figure 10:
MM440 Motor Operational Data

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5. Summary

There are significant cost benefits from employing a

motor maintenance program. These cost benefits are due to
a reduction of unplanned downtime to reduced energy costs.
A time-based maintenance program gathers statistical motor
data (number of starts, running hours, etc) and utilizes this
information to determine motor physical inspection and
lubrication schedules. A condition-based maintenance
program gathers additional real-time physical parameters
(temperature, current, voltage, vibration) to anticipate
imminent motor failures and proactively address motor issues.

Siemens Smart MCCs support either type of maintenance

program, with the following features:
• Ability to collect real-time data from the motor
controlling device
• Ability to have all relevant motor data read by the
PLC or DCS controller and presented on the operator
HMI. This data can then be printed, avoiding operator
manual data collection processes.
• Ability to gather data for time-based and
condition-based motor maintenance.The time-based
data is automatically included on all motor control
devices, but the Simocode Pro can handle optional
RTDs and vibration sensors for condition-based
monitoring programs.

Siemens Smart MCCs are a cost effective addition to any

existing maintenance program, as well as a key enabler to
initiate new motor maintenance programs.

Unique features of Siemens Smart MCC with Profibus-DP

communications include:
• Motor data is stored in the motor control devices
• Independent operation of the motor control devices
to reduce PLC programming
• Extended data and diagnostics are available for
quicker troubleshooting

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White Paper | Smart Motor Control Center | December 1, 2008

6. References

a.) “Understanding Downtime”, www.visionsolutions.com, May 2006

b.) “A Simple Way to Estimate the Cost of Downtime”, http://roc.cs.berkeley.edu/talks/LISA/ppt, Nov 2002

c.) “Motors: Planning for motor failure”, E-source Companies, LLC., 2006

d.) “Efficiency Opportunities through Motor Maintenance”, Pacific Gas and Electric Company, Apr 1997

e.) “Test Methods for Determining the Impact of Motor Condition on Motor Efficiency and Reliability”
ALL-TEST Pro, LLC., (Undated)

f.) “Extend the operating life of your motor”, U.S. Department of Energy, Sep 2005

g.) “Eliminate Voltage Unbalance”, U.S. Department of Energy, Sep 2005

h.) “FAQ about Drive Technology”, Siemens AG, 2008

i.) “Prognostics and Condition-based Maintenance”, Pacific Northwest National Laboratory, PNNL-SA-36771, (Undated)

j.) “Automated Bearing Wear Detection”, DLI Engineering Corporation, 2004

k.) “Application Manual for NEMA Motors”, http://www.2.sea.siemens.com/NR/rdonlyres/1EE7928A-37F4-44F0-9342-

C35844C09FE3/0/AppManSectionAIIRev1061608.pdf, 2008

l.) “Evaluation of antifriction bearing lubrication methods on motor life-cycle cost”, Siemens AG, Dec. 1999

m.) “Guide to Electric Motor Bearing Lubrication”, ExxonMobil, (Undated)

n.) “Hidden Treasure: Eliminating Chronic Failures Can Cut Maintenance Costs Up to 60%”. Plant Engineering Magazine, Nov
1996

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White Paper | Smart Motor Control Center | December 1, 2008

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