Artesis MCM Manual
Artesis MCM Manual
Artesis MCM Manual
WARNING
Lethal voltages and currents are present at the input terminals of this device. Accordingly, this MCM unit
should be installed and maintained only by qualified, competent personnel who have the necessary training
and experience appropriate to high voltage and current devices. MCM must be used in accordance with all
local and national codes for the installation and operation of electrical equipment.
Recommended safety precautions should be followed at all times. Both current and voltage transformers can
present lethal currents and voltages when their primaries are energized and standard practices (i.e. shorting
the secondaries of current transformers and removing voltage transformer fuses) must be respected during
installation or any subsequent service.
The unit is designed for operation in a control cabinet with restricted access to the rear terminals and should
not be used in any environment where this is not the case. MCM should not be used for the purpose of
primary protection of electrical equipment.
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MCM User's Manual
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, mechanical, photocopying, recording or otherwise, without prior written
permission of Artesis AS. No patent liability is assumed with respect to the information contained herein.
Whilst every effort has been made to ensure that the information presented in this document is accurate and
up to date, Artesis AS reserves the right to make changes without notice. Neither Artesis AS nor its
designated agents can be held responsible for any errors or omissions, or problems arising from the
application of information contained herein.
Neither Artesis AS nor its affiliates shall be liable to the purchaser of this product or third parties for damages,
losses, costs, or expenses incurred by purchaser or third parties as a result of: accident, misuse or abuse of
this product or unauthorized modifications, repairs, or alterations to this product, or failure to comply strictly
Artesis AS’s operating and maintenance instructions.
Artesis AS shall not be liable against damages or problems arising the use of any options or any consumable
products other than those designated as Artesis original products or Artesis approved products by Artesis
AS.
Product names other than those owned by Artesis AS are used for identification purposes only and may be
trademarks of their respective owners. Artesis AS disclaims any and all rights in those marks.
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MCM User's Manual Table of Contents
Table of Contents
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MCM User's Manual Table of Contents
Section IV Troubleshooting 26
1 Introduction
................................................................................................................................... 26
2 Use of...................................................................................................................................
the MCM Config utility 26
3 Fault ...................................................................................................................................
diagnosis 29
4 Servicing
................................................................................................................................... 30
Section V Appendices 31
1 Appendix
...................................................................................................................................
1: MCM Error, alarm and warning conditions 31
2 Appendix
...................................................................................................................................
2: Current and voltage sensor selection 34
3 Appendix
...................................................................................................................................
3: Connection Diagrams 36
4 Appendix
...................................................................................................................................
4: Menu settings and parameters 39
5 Appendix
...................................................................................................................................
5: Edit Settings Menu items 40
6 Appendix
...................................................................................................................................
6: Flowcharts for MCM use 45
7 Appendix
...................................................................................................................................
7: Continuous device ratings 51
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MCM User's Manual Section 1 - Welcome to MCM
1 Welcome to MCM
1.1 Introduction
MCM is a revolutionary tool in the battle to keep electric motors and machinery running at peak
performance, whilst maintaining high plant productivity levels. Used correctly, this unique instrument is
capable of monitoring three phase AC motors of all sizes and power levels to provide clear, unambiguous
indications when the performance of a particular motor (or even the machinery it is connected to) begins
to degrade. The numerous transducers employed by other, less advanced instruments have been
replaced by three current sensors and three voltage sensors, familiar to all those involved with the
measurement of electrical quantities, making the system straightforward to install and use without in-
depth training of personnel.
In addition to its unique capabilities as an intelligent condition-monitoring device, MCM can also perform
many of the functions of, and indeed replace the more traditional energy monitoring and data-logging
instruments.
For applications involving the monitoring of many motors and associated machinery, the networking
options available with MCM allow units to be connected together to a host terminal where they can all be
viewed together.
Furthermore, the monitoring software package allows examination of the various parameters MCM uses
to determine the status of a motor and to trend the parameters as a visual indication of degradation over
time.
Despite its simplicity and ease of use, like any intelligent electronic, software-based device, it is
important that MCM is installed and used correctly. We recommend strongly that you take the time to
study the information contained within the accompanying manuals and to familiarize yourself with the
operating principles and practices.
Customer service: Please contact either your supplier or Artesis AS Customer Service if you
experience any problems in the installation or use of MCM.
enquiry@artesis.com
This manual explains the basic concepts needed to install and use MCM. The appendix at the end of the
manual provides information that may be useful to the general user. For further, specific details please
2 MCM Installation
Please inspect the contents of the MCM package and ensure that they agree with the information in the
Packing list. In the event of any missing or damaged items, please contact your supplier immediately.
Check also that the power range of the MCM unit is suitable for the motor to be monitored. The device
type can be found on the MCM label. Artesis A.S. will not accept responsibility for damage caused to or
by any MCM unit that has been incorrectly installed or installed on a motor system outside the indicated
power range.
MCM has been designed to mount directly onto the front panel of the motor switchgear cabinet. Any
other usage is not recommended due to the lethal voltages present at the terminals. To mount,
insert the MCM unit into the prepared 91x91 mm cutout on the cabinet panel and push until the front of
the unit is flush with the panel. Insert the side retainers and tighten the thumbscrews on each retainer
until the MCM unit is held securely in place.
Three standard 5A secondary, current transformers of appropriate ratings are recommended for current
sensing (please refer to the appendix at the end of this manual for full specifications). The secondary
terminals of each transformer should be connected to the corresponding current measurement terminal
pairs, I11-I12, I21-I22, I31-I32, on the rear of the MCM unit.
Voltage line connections VR, VS, VT should be made directly to their respective voltage measurement
terminals V1, V2, V3 at the rear of the unit.
Please refer to the connection diagrams in the appendix at the end of this manual for further details.
The current sensors employed by MCM for inverter driven systems are Hall-effect type requiring an
external DC power supply. The motor current rating should be checked carefully to ensure compatibility
with the sensors provided. Please refer to the appendix at the end of this manual for further details on
sensor selection.
High current sensors (for currents greater than 200 A) need to be mounted separately at a convenient
location within the switchgear cabinet together with their external power supplies. Smaller sensors are
mounted on the same circuit board as the power supply and should be placed together at the chosen
location. In both cases, the cable carrying power to a single phase of the motor must be passed through
the central hole in the appropriate current sensor and secured.
The power supply ground should be connected directly to the I12, I22, I32 pairs of current measurement
terminals on the rear of the MCM unit.
Voltage connections VR, VS, VT should be made directly to their respective voltage measurement
terminals V1 V2 V3 at the rear of the unit.
Note that MCM is not recommended for use with inverters operating at a chopping frequency
lower than 2 kHz.
Please refer to the connection diagrams in the appendix at the end of this manual for further details.
Three standard 5A secondary, current transformers of appropriate ratings are recommended for current
sensing (please refer to the appendix at the end of this manual for full transformer specifications). The
secondary outputs from each transformer should be connected to the corresponding current
measurement terminal pairs, I11-I12, I21-I22, I31-I32, on the rear of the MCM unit.
Standard 100V, 110V and 120V secondary voltage transformers should be used to drop the voltage to
usable levels. Connections from the secondary outputs of the transformers should be made to the
respective voltage measurement terminals V1, V2 V3 at the rear of the unit.
Please refer to the connection diagrams in the appendix at the end of this manual for further details.
Connections to the MCM rear panel are given in the following figure. Lethal voltages can be present at
the voltage and current terminals and it is vitally important that power is removed from both the motor
and the MCM unit prior to any connections being changed.
The three motor power voltages should be connected to the corresponding measurement terminals on
the MCM rear panel (R phase to V1, S phase to V2, and T phase to V3) using the connectors provided.
Similarly, the IR, IS, IT connections from the current sensors should be made to the appropriate current
terminal pairs, I11-I12, I21-I22, I31-I32, on the upper part of the rear panel. It is not essential that the all three
sets of phases have the correct phase relationship as the phase ordering is determined by MCM.
The order of these voltage and current pairs is not important as MCM determines the correct ordering
when CHECK MOTOR is first run on the device
A circuit breaker should be provided on the power line in close proximity to the MCM
unit. The circuit breaker should be clearly marked as the power switch for the device.
Please note that in order to function at its full capability, MCM requires that the case be
connected using a low impedance cable (12 – 14 AWG cable is recommended) directly to a
high quality ground via the ground terminal on the power connector. If a suitable ground is not
provided, fault free operation within specifications cannot be guaranteed.
Once the motor connections have been made to the rear panel, power should be applied to the unit.
MCM requires between 85 and 240VAC obtained from a single phase, neutral and ground. At this stage,
the Power indicator at the left of the front panel will light. If this does not occur, please check that the
correct voltages have been applied.
Immediately on application of power, the LED condition indicators should briefly flash and activity should
be seen on the main display. The text "Initialising" followed by a series of dots will appear.
"Initializing.... "
After a few seconds, the display should indicate that it is in the IDLE mode. MCM is now ready for use.
When using a device for the first time the message "Bad flash data! Press Clear" may be displayed. In
this case press the CLEAR button several times until the message disappears. Once a valid learn mode
has been completed, this message should not occur again.
MCM can be installed with standard soft-starter systems provided that they are automatically bypassed
immediately after motor start-up and during subsequent use. Un-bypassed, soft-starter systems can
introduce considerable distortion into the current waveforms and thus prevent MCM from modeling the
properties of the motor itself. If MCM is to be used with such a system, it is essential that the maximum
current limit of the starter be above the nominal running motor current so that it is bypassed effectively
during all normal operation. MCM should never be used on a system that employs soft-starters for
speed control or other un-bypassed uses. Please refer to the diagrams in the appendix for details of
the connections needed for soft starter systems. Soft-starters should always be bypassed.
Using MCM with inverter driven motors requires the same voltage connections specified for line driven
systems. External Hall-effect current sensors must be used with inverter systems, as normal current
transformers have insufficient bandwidth for use with the range of frequencies obtainable from inverters.
Please refer to the diagram in the appendix for details of the connections needed for inverter driven
systems.
3 MCM Use
3.1 Introduction
Use of MCM is both simple and straightforward once the basic concepts and principles are understood.
This section of the manual is designed to introduce these concepts and to demonstrate how MCM is set
up, how to check all the connections and settings, how MCM learns the characteristics of the system it
will monitor and finally how to actually monitor the motor system. It is recommended that first time users
read this section carefully, as successful operation requires that MCM is set up and used correctly.
Flowcharts for the main operations are provided in the appendix at the end of this manual to help users
navigate their way through the various steps involved with setting and running MCM for the first time.
Commands are input by pressing one of the six selection buttons on the front of the unit, UP, DOWN,
LEFT, RIGHT, ENTER and CLEAR. For instance, the user can cycle through the various modes (IDLE
to CHECK MOTOR to RUN to RESUME … and finally back to IDLE), by repeatedly pressing the UP
button. A particular mode can be selected by pressing ENTER when the desired mode is displayed on
the LCD. The menus are set up on a hierarchical basis, with each level representing commands of the
same precedence which the user can cycle through by pressing the UP or DOWN buttons. Pressing
CLEAR has the effect of stopping a particular action and rising up a level in the hierarchy. Only Edit
Settings has nested hierarchy levels more than two deep. In general whenever ENTER or CLEAR is
pressed, it will be necessary to confirm the action with a second press of the button; pressing the other
button (i.e. CLEAR after ENTER and vice versa) will cancel the action.
Master reset:
When first installed, the MCM unit will be configured for the default, factory settings which will need to be
changed prior to use. At later times, the factory settings can be restored by pressing and holding down
the LEFT button for about 4 seconds during power up of the device, until the string; Press ENTER for
general reset appears. At this stage pressing ENTER will initiate the reset. Pressing any other button
will cause the reset to be ignored and the device will continue.
To configure the unit, select the Edit Settings mode and press and confirm ENTER. In order to proceed
further, it will be necessary to enter a password. The factory setting for this password is the string “m“
and can be entered using the UP and DOWN buttons to cycle through the alphanumeric characters (‘a’
through ‘z’, ‘0’ through ‘9’). The LEFT and RIGHT buttons are used to shift the active character in the
string. To input the password “m”, repeatedly press the UP button until the letter ‘m’ appears in the first
position. Press and confirm ENTER and then press ENTER again to enter the Edit Settings menu.
It is recommended that at a later time the password be changed, in order to prevent unauthorized
access to the device.
At this level the following Edit Settings menu items are accessible:
Menu paths:
Throughout this manual, paths to menu items are represented by the word MENU: followed by the list of
sub-menus required to reach the item separated by a forward slash. For example the path of the Parity
value given in the preceding paragraph would be given as:
The forward slash can be thought to represent the action of pressing and confirming ENTER.
In addition, canceling any of these modes by pressing CLEAR also requires the user to supply a
password. All passwords are the same as that used to access Edit Settings.
3.3.2.1 First time use
Before MCM can be used for the first time it is necessary to change various settings from their default
values (a table outlining the MCM settings is shown in the appendix). Values relevant to the connected
motor must be set for the quantities described in the following sections.
Hall-effect current sensors and assemblies supplied with MCM should be accompanied by a calibration
document containing the sensor’s calibration factor. The values of each calibration factor should be
entered into the correct setting under the Calibration menu. It is important that the correct factor be
entered for each channel, as MCM will not function correctly if the calibration factors are incorrect.
For channels connected to transformer sensors, the calibration factor should be equal to the nominal
ratio of the primary to secondary turns. For example a 100A current transformer with a 5A output and a
single primary turn would require a calibration factor of 20. The same transformer with two primary turns
would require a calibration factor of 10. A 6500V voltage transformer with a nominal secondary voltage of
100V would require a calibration factor of 65. Any channel connected directly to the motor without an
external sensor (i.e. voltage connections on low voltage units) requires a calibration factor of 1.
3.3.2.3 Motor settings
It is recommended that the motor serial number (or any other short identifier string) be entered as a
means of identifying the motor to the software. This is not obligatory, and both the networking software
and MCM can function without this information.
Having configured MCM for a particular motor, it can now be used for its intended purpose of monitoring
and assessing the condition of the motor. In general, this involves first running MCM to measure and
learn the properties of the motor and then running MCM in its test mode to perform the actual
monitoring. Without the learning period MCM has insufficient information on which to base its
decisions as the motor ages and will not perform to its specifications. For this reason, MCM
ensures that a valid learning period is first performed before allowing the user to request the device to
monitor the motor.
MCM divides warning messages into the categories of warnings, alarms and errors. Warnings inform the
user that non-critical conditions have arisen that the user should be aware of but do not affect the
performance of MCM. Alarms provide information specific to the motor being tested and are indications
of faults caused by incorrect connections to the motor, the supplied line voltage and/or motor currents
being outside the specified limits and other conditions that prevent MCM from correctly determining the
state of the motor. Alarms do not cause MCM to stop monitoring completely, but generally are
indications that there is something that needs to be investigated and possibly changed before MCM can
function to its full extent. In some cases an alarm may indicate a transient event such as high line
voltages, which although damaging to the motor in the long term, do not indicate an immediate need for
action. Of course if the frequency of such events is sufficiently high, the cause should be located and
corrective action taken to remedy the problem. It is important to realize that when an alarm is
displayed, MCM cannot monitor the motor status. It is therefore important to ascertain the cause of
the alarm at the earliest opportunity.
An alarm is indicated on the front panel of MCM by the message Alarm followed by a hexadecimal value.
The bits of the hexadecimal value refer to which alarm is raised. Repeatedly pressing the RIGHT or
LEFT buttons cycles through a list of all active alarms. Please refer to the appendix for a complete list of
possible alarm conditions and their remedies. The measured physical motor values can be viewed during
an alarm by pressing the UP or DOWN buttons. This is often useful in determining the reason for an
alarm.
STATUS LED
Fault Severity
STRING No
LEARN MCM has insufficient data to assess the status of equipment
NORMAL 1 Motor is healthy or level of failure is under alarm thresholds
There is a changing on the supply voltage of the motor. Temporary
2 changes in supply voltage cause this alarm. If alarm is persistent check;
WATCH LINE
harmonic levels, capacitors, isolation of cables, motor connector or terminal
slackness, loose contactors, etc.
There is a possibility of load changing : If the process load has not been
altered deliberately, check for leakage, valve & vane adjustment, pressure
WATCH LOAD 3
gauge faults, manometer, dirty filters (fans, compressors). If the process is
altered deliberately, MCM/PCM should be updated.
Plan Maintenance ( First Level Alarm) : There are developing mechanical
EXAMINE 1 4 and/or electrical fault(s). Although the level of the failure is not serious, the
maintenance should be done in next planned stop or latest in 3 months
Do Maintenance (Second Level Alarm) : There are developing
EXAMINE 2 5 mechanical and/or electrical fault(s).Maintenance and corrective action
should be performed as soon as possible.
When monitoring a motor in test mode (MONITOR, IMPROVE or UPDATE), MCM provides a status
indication on the right side of the upper display line. This consists of one of the items in the table above.
In addition, one of the five LED indicators on the front panel is lit showing the color corresponding to the
motor status in the table above. As with all grading schemes, there is always some overlap between the
bands and it is possible for a healthy motor sometimes to indicate a fault severity greater than 1.
However, in healthy motor systems such false alarms should be transitory and prolonged display of a
fault should indicate the need for maintenance. A prolonged fault indication should always be
investigated.
On first use of MCM and each time any maintenance is performed on the motor, it is essential that the
motor together with its connections are checked by running the CHECK MOTOR function. In this mode
MCM performs a short check on all motor connections to determine the phase ordering and that a motor
is connected and running. It also checks among other things, that the voltage and current levels are
within set limits, and that the phase angle between the V1 and I11 - I12 channels is appropriate. If MCM
detects that some condition is not met, an alarm is raised which the user should investigate and remedy
before proceeding further.
Please note that if the Local Lock out setting is ON it is necessary to supply a password before access
to the CHECK MOTOR mode is granted. The password is the same as used to access the Edit Settings
menu.
Once CHECK MOTOR has finished, it will display either the message "Motor values" or a warning or
alarm indication. At this point the UP and DOWN buttons can be used to cycle through a list of
calculated physical parameters. If an alarm is present, pressing LEFT or RIGHT buttons will cycle
through the list of alarms. Many of the alarm conditions relate to the calculated physical values and it is
often useful to check the calculated values of the relevant parameters when trying to understand the
origin of an alarm condition. Pressing CLEAR will return to the IDLE state.
The software utility MCM Config found on the companion cdrom, can be of help diagnosing problems
during initial Edit Settings. The program should be installed on a portable pc and the pc connected (via a
RS232 - 485 converter) to the communications port on the rear of the MCM device. Using the software it
is possible to upload and display the voltage and current waveforms measured by MCM. Inspection of
these waveforms can reveal problems caused by missing phases, phase ordering, phase imbalance etc.
Please refer to the MCM Config documentation and to the trouble shooting section of this manual for
further details.
When the CHECK MOTOR menu option is selected, MCM first determines the relative order of the
voltage phases using the V1 channel as an arbitrary reference. It then attempts to place the current
channel pairs in the correct order and polarity. The order determined by MCM can be displayed by
entering the EDIT SETTINGS menu and selecting:
On this menu, the voltages are denoted by the letters R, S, T and currents by r, s, t. A – sign preceding
each letter indicates that the corresponding signal has an extra 180º of phase shift (i.e. that the polarity
of the signal is reversed). Similarly, a + sign preceding a letter indicates that the polarity is correct. For
example:
The above phase ordering display would indicate that relative to the first voltage (R) phase on input V1,
the S and T phases (on V3 and V2 respectively) are reversed. The order of the current inputs is also
incorrect with IS connected to I11 - I12, IR connected to I21 - I22 and IT connected to I31 - I32. Furthermore, the
polarities of the two currents, IS and IT , have been reversed (I11 has been exchanged with I12 and I31 with I32).
Please note that once MCM has determined the correct phases, the user should not change the input
connections without running CHECK MOTOR again.
The algorithm used by MCM to determine the phase order yields two solutions depending on the motor
loading and extra information is required to obtain the correct sequence. To this end, MCM compares
the measured RMS values for the currents with the nominal current entered by the user. If the ratio of the
measured current to the nominal current is greater than the value of the Load threshold (expressed as a
percentage), the motor is assumed to be working under loaded conditions and the appropriate solution is
chosen. Otherwise the motor is assumed not to be loaded. It is thus important to enter an accurate
value for the nominal current. Even so, it is still possible for MCM to choose the wrong solution which will
yield unrealistic values for the phase angle when the loading on the motor changes in use. MCM
provides the possibility of overriding the detected phase sequence from the menu item Order Override
under:
Changing the value of this item from OFF to ON allows the detected phase ordering to be altered by
moving the cursor to the required position and scrolling UP/DOWN to select the desired value.
It is also possible to fine-tune the algorithm by altering the value of the load threshold. A higher value will
tend to favour the unloaded solutions and vice versa. The load threshold can be found under:
LEARN:
MCM should learn the motor under normal operating conditions. The LEARN period consists of a preset
number of data acquisition cycles and periods of data analysis. Once the preset number of cycles has
been reached, the acquired and pre-processed data are further processed to produce a database
consisting of a collection of data sets representing the behavior of the motor system under the load
conditions that the motor has met in practice. It is therefore important to have the motor operating under
its expected running conditions during a learning period. In order to cover adequately the range of load
conditions experienced by a motor system, a sufficient number of acquisition cycles or iterations is
required. It has been found that 4000 iterations provides adequate coverage under most conditions and it
is recommended that between 3000 and 4000 iterations are used. Since additional learning can also be
performed if needed during the testing phase, a larger number of learning iterations is not generally
required. The number of learning iterations can be set from the menu path:
IMPROVE:
Selecting RUN from the main menu will initiate a new LEARN period. If data from a previous leaning
period exist, the following message will be displayed:
The user should press the CLEAR button if it is not desired to overwrite the existing data and ENTER if it
is.
Once the initial learning period is complete, the MCM unit automatically will try to improve its estimation
of the motor characteristics. To update the database obtained during the learning mode for different load
and line conditions until sufficient data have been amassed, as determined by the number of Improve
iterations set from the menu path
the motor, it is likely that the alarms represent transient conditions present on the power lines. However,
it is suggested that any alarm representing a condition that could affect the performance of the motor
should be recorded and investigated as a potential cause of motor degradation. As in CHECK MOTOR, if
an alarm is indicated, the most recent physical values available for the motor can be displayed using the
UP and DOWN buttons. Examination of these values can often indicate the precise reason for the alarm
condition. A complete list of alarm conditions can be found in the appendix at the end of this manual.
Canceling running:
All the operating modes LEARN, IMPROVE, MONITOR and UPDATE can be stopped and started at
any time without significant effect on monitoring performance, by pressing the CLEAR button (and
providing the correct password if Local Lock out is ON). Subsequent restart of MCM can be achieved by
selecting RESUME from the main menu, which will cause MCM to continue in its incomplete mode at
the point of interruption. Thus if it is necessary to stop MCM for any reason, it can be restarted without
affecting any existing data.
UPDATE:
At subsequent times it may be desirable to learn a new operating point of the motor. This can be done
using the UPDATE function. This can be reached either from the main menu in IDLE mode or by
pressing first the RIGHT and then the ENTER button during MONITOR.
If it is necessary to learn the new operating conditions of the motor in order to add them to the existing
database, UPDATE can be started in two ways. Firstly, in IDLE mode, the Update option should be
selected and ENTER pressed. Secondly, from MONITOR, the RIGHT button should be pressed to
display the message:
It is possible to customize the behavior of MCM by adjusting various settings. As usual a valid password
must be supplied before the Edit Settings menu can be entered. The following table summarizes the
settings that can be changed together with their significance. It is recommended that the original values
of each setting be recorded prior to changing them. After changing certain settings it may be necessary
to relearn the motor.
MCM uses a model based fault detection and diagnostics technique. In this technique, the expected
dynamic behavior (model) of the three phase system under varying conditions, such as load, is
determined and compared with the measured dynamic behavior to monitor abnormalities. MCM first
learns the system for a period of time through acquiring and processing the real-time data from the
system. The data is processed using system identification algorithms for the calculation of expected
dynamic behavior and the model parameters. The changes in the parameters of the system indicate to
abnormalities developing in the system. Further processing of these parameters is used for diagnosis.
As opposed to traditional vibration and current signature analysis, this approach uses a cause-effect
(input-output) relationship and therefore immune to the surrounding noise or noise in inputs. Also the
difference between expected and actual behavior filters out and enhances ONLY abnormalities generated
by the system which allows to earlier and accurate warnings. The expert system approach eliminates
the needs for data base or record keeping, expert personnel, time consuming data gathering and
analysis. It provides comprehensive (mechanical and electrical as well as driven system) fault coverage
though it measures only voltages and currents.
MCM uses the electric motor of the equipment as a sensor. Therefore, any fault of the equipment that
affects the motor or the three phase system is also observed by MCM.
MCM first learns the motor-based system for a period of time by acquiring and processing the motor
data. The results of the processed data are stored in its internal database and a reference model is
established. This reference model basically consists of model parameters, their mean values and their
standard deviations. While monitoring, MCM processes the acquired motor data and compares the
results to the data stored in its internal database. If the results obtained from the acquired data are
significantly different from the reference model, MCM indicates a fault level. The level is determined by
taking into account the magnitude and the time duration of the difference. In total, MCM monitors and
compares 22 different parameters (model parameters). These parameters are classified into three
groups, electrical parameters, mechanical parameters and fit parameters. These are explained in detail
in the following sections.
1. Electrical Parameters
There are 8 parameters in the first group which are called electrical parameters. These are the network
equivalent parameters and are correlated to the physical parameter of the motor, like inductances,
resistances, etc. They are sensitive to electrical faults developing in the motor. MCM evaluates and
analyzes the differences between the model parameters at any instant and the average value of the
same parameters that are obtained during the learn stage. These differences are normalized with respect
to their standard deviations obtained during the learn stage. Hence the values indicate the number of
standard deviations they are away from the average values obtained during the learn stage. If they
exceed threshold values, than an alarm is given. The changes in their values are associated with the
faults that are developing in the system. As an example an isolation problem in winding will affect the
parameters associated with resistances. Their change will allow MCM to detect the isolation problem at
an early stage. Though they are primarily used to detect electrical problems, they also can indicate
mechanical problems as well. As an example an imbalance or gear problem would cause dynamic
eccentricity in the air gap. This eccentricity will cause a change in the induction parameters and
therefore in the model parameters. By monitoring the changes in these model parameters imbalance can
be detected at an early stage. This eccentricity eventually affects bearing and it will also eventually
damage the bearing. Therefore its detection at an early stage can prevent further damages
The electrical parameters are further classified in two groups, E1 (internal) and E2 (external)
parameters. Electrical parameters 1-4 (E1) indicate problems associated with rotor, stator, winding etc.
while 5-8 (E2) indicate electrical supply problems such as voltage imbalance, isolation problem of
cabling, capacitor, motor connector, terminal slackness, defective contactors etc.
2. Mechanical Parameters
The parameters in the second group are sensitive to mechanical faults such as load imbalance,
misalignment, coupling and bearing problems. They are called Mechanical Parameters 1-12. These
parameters are obtained from the frequency spectrum of the electrical signals by extracting information
from the line current and voltage supplied to a motor. The variances in the stator-rotor air gap are
reflected back in the motor’s current through the air gap flux affecting the counter electromotive force.
Therefore current carries information related to both mechanical and electrical faults. Hence faults will
exhibit a change in the frequency spectrum of the current in specific frequencies.
MCM uses the power spectral density (psd) obtained from the differences between the expected current
obtained from the model and the actual current. These differences include only abnormalities generated
by the motor. Therefore, they are immune to the noise or harmonics present in the supply voltages. The
mechanical parameters indicate the power level of the difference between measured and estimated
current at frequencies they occur in terms of number of standard deviations. If they exceed the threshold
The mechanical parameters (M1-M12) correspond to the 12 maximum values obtained in the frequency
spectrum. These parameters are also used for diagnoses. The frequencies they occur indicate the type
of fault, i.e., an imbalance, loose foundation, oil whip, fan blades, inner or outer race of bearing etc.
These parameters provided to the user for trending and diagnostic purposes.
MCM employs two different measures for calculating the motor status: Motor Status 1 and Motor Status
2. In addition to these, MCM also monitors load and line changes and summarizes the results of this
monitoring via the Load line status parameter. Motor Status 1 monitors the maxima of each of the three
groups of parameters introduced in the previous section, over a window (with a default window size of 14
iterations in a monitoring mode) and compares them with four different internal thresholds calculated
following the initial learning phase. Motor Status 1 takes value between 1 to 5 and is calculated as
follows:
Motor Status 2 also takes values between 1 and 5. The calculation of Motor Status 2 is based on
counting the frequency of the values of Motor Status 1, that are greater than one, and the frequencies of
any load and line changes over larger windows. Window sizes and frequency thresholds used for the
calculation of Motor Status 2 are selected so that temporary a change in Motor Status 1 does not cause
any change in Motor Status 2.
The Load line status parameter of MCM takes values between 0 and 15. Its possible values correspond
to combinations of the bits of a binary number, with each bit having the significance given in the following
table:
Thus a Load line status value of 9 would result from the arithmetic sum of 8 and 1, and would correspond
to conditions 0 and 3 holding and conditions 1 and 2 being false. This would mean that both the voltage
values and the loading conditions differ from the conditions met during the learning period but that the
voltage balance and voltage fluctuations were consistent.
The motor status values displayed on the front panel of the MCM unit and reported by the MCMSCADA
monitoring software are actually the values of the Motor Status 2 parameter. Motor Status 1 is not
available from the front panel and can only be monitored using the trending plots of MCMSCADA. The
LED indicators on the front panel of MCM correspond to the values of Motor Status 2, starting with OK
(value of 1) on the left and increasing up to Examine 2 (value of 5) on the right.
3.4.9.2 Changes in line voltages
Motor status alarms associated with the changes in the line conditions are indicated by the "Watch
Line" message on the front panel, the second (3.) LED indicator being lit and Motor Status 2 having the
value of 2. They are usually temporary in nature and generally the user does not need to take any action.
However, it is recommended that when this status level occurs, the user should at least assess the
extent of the change in the line conditions, as significant changes in the line voltages and currents may
be dangerous to the motor. If the line status change is persistent, the user should assess the root cause
of this change. For instance, it may be due to a problem in the contactors or for inverter driven motors
the settings of the inverter may have been changed. In any case, if the root cause cannot be remedied
easily and quickly and the new voltage supply condition presents no danger to the motor, the user has
the option to send MCM to the UPDATE mode. This will allow MCM to learn the new voltage supply
conditions, after which the status will eventually return to normal.
3.4.9.3 Load changes
Motor status levels associated with changes in the loading conditions occur with the "Watch Load"
Message on the front panel, the second (orange) LED indicator being lit, and Motor Status 2 taking a
value of 3. They are also temporary in nature but they should be treated more carefully than line
changes, as some faults developing in motor based systems can cause changes in the loading
conditions. For instance, leakages from pump seals can cause pressure drops, which will be interpreted
by MCM as changes in the loading conditions. Similarly, clogging in a pipe or membrane or an increase
in the friction of moving parts will be detected as changes in the apparent load. It is, therefore, important
to assess the root cause of the load change. In certain cases, (for instance, closing or opening a valve or
changing a pipe), the changes in the loading conditions are intentional and should already be known by
the user. In such cases, the user should send MCM to the UPDATE mode so that it will learn the new
loading conditions. When no obvious cause can be found, it is likely that a fault is indeed developing and
the situation should be monitored more carefully .
3.4.9.4 Error messages
Unlike alarms, errors refer to failures of the MCM hardware and software rather than the monitored motor.
When MCM discovers an error condition it makes several attempts to recover, and only if these attempts
are unsuccessful is an error message generated. All errors stop MCM from functioning and must be
cleared before proceeding further. Errors are indicative of a serious problem within MCM and their source
should always be investigated. An error indication consists of two parts: Firstly the displayed error
string; and secondly the associated error number. When reporting device malfunctions, please be sure
to include both the message and its associated number. Please refer to the appendix for a full list of
error messages.
switching on the device power or pressing and releasing the reset button at the rear of the device. Note
that the unit must be in the IDLE state before removing the power or pressing the reset button or this
procedure will not work. The button must remain held down for at least four seconds until the message:
appears on the display. At this point ENTER should be pressed to perform the reset. If this does not
clear the error, it is likely that the MCM device is experiencing a hardware fault and that the unit should
be returned for servicing.
Please note that performing a hardware reset in this manner resets all settings to the factory
defaults and all previously saved information will be lost. This includes all learning mode and
Edit Settings data, so a hardware reset should be used only as a last resort.
3.4.9.5 Using the relay output
MCM is equipped with two connections on the rear panel internally connected to a low power, normally
open relay. Closure conditions of the relay can be programmed from
and selecting the desired fault level. During MONITOR, IMPROVE and UPDATE, the relay will become
active anytime the fault level rises above the selected relay level, and the following message will be
displayed:
"Relay active"
When the relay is active and the previous message displayed, pressing the LEFT or RIGHT buttons
cycles through the messages:
"Acknowledge"
"Reset relay"
Pressing the CLEAR button while either of these messages is displayed deactivates the relay. Selecting
Acknowledge will cause the relay to activate again only when the motor status exceeds the current value
whilst Reset relay will allow the relay to activate again when the same preset conditions are next met,
possibly as soon as the next data cycle.
MCM can be connected to a PLC or other monitoring system such as MCMSCADA via the RS485 port
on the rear of the device. Artesis A.S. makes available its proprietary protocol on request in document
MCM-OP-SI-EG-0002 entitled MCM System Communications Protocol Document for End Users. Please
contact Artesis A.S. to obtain this document.
MCM uses 2 or 4-wire RS 422/RS485 communications with optically isolated (to 2500V) inputs and
outputs. MCM is configured as a slave device and needs to be addressed before it will communicate over
the bus. It will support communication rates of up to 19,200 Baud over distances exceeding 1000m, but
this rate can be degraded if the environment is especially noisy.
For 2-wire connections, each terminal pair Tx+ - Rx+ and Rx- - Tx-must be connected together on
each MCM device. In some cases, particularly with slow PC hosts that do not release the transmit line
rapidly; it may be necessary for the MCM device to delay its response. This can be achieved by
adjusting the value of the menu setting:
In the diagrams given above, the terminals marked 0 on each MCM device are connected together and
with the 0 terminal on the converter. Internally, these terminals are connected to the local ground via 100
Ω resistors. This optional connection is provided in order to have a quality return path for the differential
signals, which can in some circumstances reduce noise and lead to better communications. In cases
where the ground quality is adequate, this connection can be left unused. Similarly, terminating resistors
between the terminals on the last device in the daisy chain (star topologies are not recommended) are
indicated. These resistors (typically of value 120 Ω, depending on the impedance of the cable used)
may not be needed in short networks with few devices, but at higher baud rates and as the network
length increases, their inclusion becomes essential.
4 Troubleshooting
4.1 Introduction
During installation and running a number of checks should be made to ascertain whether the MCM unit
is performing correctly and to determine possible causes if not.
The MCM Config software is a simple test utility provided by Artesis for examination of waveforms, and
can connect to a single MCM unit using the RS485 serial line on the rear of the instrument. If a network
is available, MCM Config can be installed on the host computer, otherwise a portable laptop machine
equipped with a suitable RS232 – 485 converter should be made available for this purpose.
There are two types of connection options which are available. If your PC is directly connected to the
RS485 <-> RS232 serial converter via a serial port, then make sure that Serial is selected, and enter
serial communication settings in the relevant boxes below. The default settings are:
· Port : COM1 (This depends on your PC's setup, but most PC's have only one serial port which is
addressable at COM1 by default)
· Baudrate: 19200
· Parity: EVEN
· Data Bits: 8
· Stop Bits: 2
If you are going to connect to a remote MCM or MCM network using a TCP/IP connection, then make
sure that TCP/IP is selected, and enter the TCP/IP connection settings in the relevant boxes below.
These will depend on your network configuration.
When you hit Connect button, Configuration utility will automatically try to connect to the default address
of 1, and display the status of the connection inside the Connection Status box. If the MCM has a
different address, select the appropriate address from the Address selection box. Configuration utility
should connect to the device and display its status as green or red boxes inside the MCM Mode, MCM
Status and Motor Status boxes.
You can send commands to the MCM by clicking on the Select Command box, which brings up a list of
available commands. Choose commands from the list below to test various functions of the MCM.
Command Explanation
Get Status Updates the status information
Go Idle Sends MCM to the IDLE state
Check Sends MCM to the CHECK state
Update Sends MCM to the UPDATE state
Resume Sends MCM to the RESUME state
Run Sends MCM to the MONITOR state
Get Alarm Gets alarm information from the device
Get Error Gets error information from the device
Get Warning Gets warning information from the device
Get Version Gets MCM's version
Take Data Starts acquisition of VI data for later viewing. This also enables upload
status elements
Get RMS Gets RMS values from the device
Get Settings Gets MCM settings and displays all the setting values for checking &
editing
Download PSD Data Gets PSD values from the device
Download VI Data Downloads previously recorded VI data for viewing. Use of Take Data is
recommended for latest VI values.
Check system response by sending a Get Status message. This is done by selecting Get Status from
the Command selection combo box and pressing the Send Command button. If "Response Received"
message dos not appear in the Connection Status box in the amount of time specified earlier as the
timeout interval, check the connections, cabling, baud rate, pc ports etc.
Waveforms of the last data acquired by MCM during data acquisition can be uploaded to the pc for
inspection as follows:
Send the MCM unit to IDLE mode by selecting the Idle command from the Command Selection combo.
Note that the unit always sends the current data stored in its memory so after any changes to the input
conditions it will be necessary to refresh the stored data by sending the unit to CHECK MOTOR mode
using the Check Motor command.
Initiate the upload mode by sending the Take Data command. The software will wait 6 seconds and then
enable the Upload button. Press the Upload button and observe the "Data Received : " text displayed
together with the current number of data points. The progress bar in the Upload Panel will indicate how
much data has been downloaded. When sufficient data are available, press the Cancel Upload button
to display the voltage and current waveforms. The view can be zoomed using the mouse to define the
desired region whilst holding down left button. Pressing the right button restores the view.
Voltage and current waveforms corresponding to the same phase are plotted in the same color. If the
Display calibrated data checkbox is selected, the data are scaled according to the device calibration.
Deselecting this box is sometimes useful to view both the voltage and current waveforms together. The
following waveforms are scaled.
You can turn off any of the waveforms you do not wish to see by disabling the appropriate checkbox next
to the label indicating this waveform.
A number of common problems can be diagnosed by inspection of the measured waveforms, and it is
good practice to check the waveforms of each unit as part of the commissioning process. With the
motor running, and power applied to MCM:
Voltage phases should have the correct RST phase relationships, separated by 120º. The current
phases should be in the same order as the voltage phases and also separated by 120º. Any phase
ordering, missing or duplicate phase problems should immediately be seen from the waveform display.
For star connected motors, it is essential that the phase angles between corresponding voltages and
currents lie between 0 and 90º. Motors connected using the delta topology have an extra 30º phase shift
and the current phase angles should lie between –30 and +60º. In either case, check that the motor
topology has correctly been entered on the MCM front panel and that the currents do indeed correspond
to the correct voltages. It is important to perform this test with the motor under loaded conditions as
loading can significantly affect the measured phase angle.
For delta connections check that the sensors are measuring the line rather than phase currents, (i.e. the
sensor is situated on the line side of the contactor) as these differ. For star connections the two are the
same.
If the amplitude of the R phase current waveform varies excessively, MCM will not be able to find stable
data and will give the unstable line alarm. If the problem lies with the input signals, it should be
immediately obvious by inspecting the displayed waveform. In the case of excessive variation of the R
phase current amplitude, the Current Instability threshold should be incremented from its default value of
15% in steps of 5% up to a maximum value of 50% using the MCM front panel. If the variation exceeds
this level, please contact Artesis.
All phases should be checked for correct, clean, zero crossing. If a waveform appears to be regular and
sinusoidal over consecutive half periods, but does not cross through zero, it is likely that the zero
crossing detection hardware is defective and the unit should be replaced. If however, the waveform is
irregular the problem could lie with the sensors. In this case check all cabling and power supply
connections. If these are satisfactory, return the unit if the problem lies with a voltage channel. For
current channels, try replacing or swapping the sensor with another one. If the new sensor does not work
the problem is internal to the MCM unit and it should be returned to Artesis.
If any phase has a marked difference in amplitude to other similar phases, the calibration constant for
that phase should be checked. If no external sensor is attached (i.e. for low voltage motors) the
calibration constant should be 1. If the calibration is correct, the sensor may be defective and should be
changed.
Check the current balance levels using the MCM front panel. A value below 15% is acceptable, but
above 15%, the Total Harmonic Distortion (THD) on all current phases should be checked. Normal levels
for THD can be up to 6% depending on conditions. For values higher than this level check whether the
distortion originates from the motor or the line, by measuring the THD present at other motors connected
to the same supply. If the same level for THD is measured at other motors, the line supply is suspect
and should be investigated as high levels can damage motors in the long term. Otherwise, the motor is
probably already damaged in some way and should be investigated.
Check the voltage imbalance levels using the front panel. A value below 5% is deemed satisfactory.
Above this level, check the THD levels on each voltage phase. Levels above 5% should be investigated.
The ability of MCM to detect faults will be reduced as voltage imbalance increases.
Check that all waveforms disappear when power is removed from the motor.
4.4 Servicing
MCM contains no user serviceable parts and must be returned to either Artesis A.S. or its designated
agents if repair is needed.
5 Appendices
Error conditions:
First byte Minor code
Format
Second byte Error type
Error types
Error no. Error type Description
0x010000 Memory The dynamic memory manager failed in a request to allocate a block of
allocation error memory
0x020000 General error An unexpected or general error occurred
0x040000 Zero division The algorithm attempted to perform a division by zero
0x080000 Flash Write There was an error attempting to write to flash
0x100000 Illegal square The algorithm attempted to form the square root of a negative number
root
0x200000 Initialization Initialization was not properly finished, or an error occurred
error
0x400000 No data error There is no data present
0x800000 Data An error occurred during data acquisition causing insufficient data to be
acquisition acquired
error
0x01000000 Parameter An illegal value was calculated for an algorithm parameter
error
0x02000000 Flash error An attempt to read or write from the flash RAM gave an error indicating
a faulty flash. The device can only be restarted by removing power and
performing a general reset
0x04000000 Cluster error An illegal cluster value was detected.
0x08000000 Flash data Data stored in the flash RAM is corrupted and cannot be used. This
error error is generated during both learn and test modes following an attempt
by the algorithm to recover from another fault
0x10000000 Stability error Clusters used by the algorithm are inherently unstable
0x20000000 Voltage range An illegal voltage value was detected
error
Alarm conditions
Alarm no. Alarm type Description
0x0001 Voltage balance Voltage phase imbalance exceeds the set threshold
0x0002 Current balance Current phase imbalance exceeds the set threshold
0x0004 Voltage range Ch 1 Voltage greater than the upper threshold
0x0008 Voltage range Ch 2 Voltage greater than the upper threshold
0x0010 Voltage range Ch 3 Voltage greater than the upper threshold
0x0020 No voltage Ch 1 Voltage less than acceptable (No voltage) limit
0x0040 No voltage Ch 2 Voltage less than acceptable (No voltage) limit
0x0080 No voltage Ch 3 Voltage less than acceptable (No voltage) limit
0x0100 High current Ch 1 Current exceeds upper threshold limit
0x0200 High current Ch 2 Current exceeds upper threshold limit
0x0400 High current Ch 3 Current exceeds upper threshold limit
0x0800 Motor not running All currents were measured below their acceptable (No current)
limits
0x1000 Motor connection One or more currents were measured below their acceptable limits
fault
Warning conditions
Warning Warning type Description
no.
0x01 Test frequency (MONITOR, IMPROVE, UPDATE only) The measured frequency was
range different to (i.e. outside the threshold of) the LEARN frequency
0x02 Residual error An unexpectedly large value was calculated for the modeling error. This
is generally an indication of an unstable line condition and will usually
pass
0x04 Data size reset Values for some quantities were checked and found to be outside their
allowable limits. The values were reset to the upper or lower limits
0x08 Phase ordering Phase ordering is different from the values set
0x10 Unstable Instability was detected for the system
system
When selecting a current sensor, both the maximum current the motor will handle in practice and the
type of motor drive used should be considered. Systems employing an inverter will generally limit initial
inrush to a maximum of about 150% of nominal current. With a soft-starter system this limit will probably
be 400%. Sensors must be able to withstand the maximum expected inrush currents and should be
selected accordingly.
Sensors should be selected such that the nominal motor values for current and voltage are around 70%
of the corresponding sensor rating. Alternatively, for current transformers, the secondary current at
nominal motor current should be between 3.5 – 4.5A and for voltage transformers, the secondary voltage
should be between 70 - 90V at a nominal motor primary voltage. Failure to do so will result in a loss of
sensitivity and the ability of MCM to detect motor degradation or change.
Current Transformers
Upper Voltage (kV) Class Secondary output Standards
range (A)
IEC ANSI
0.72 0.5 0-5 60044-1 57.13
7.2
12
0.5 0-5 1851987 CS71978
17.5
24
Voltage Transformers
Upper voltage (kV) Class Secondary output (V) Standards
IEC
12 0.5 0-100 1861987
24
Connection diagram for low current (up to 5A) line driven motors (MCM LV Line):
Connection diagram for low voltage line driven motors with current transformers (with nominal
current above 5A & MCM LV Line):
Connection diagram for low current (1 - 5A), low voltage, inverter driven motors (MCM LV
Inverter):
Connection diagram for low current (6 - 200A), low voltage, inverter driven motors (LEM Sensor
& MCM LV Inverter):
Connection diagram for high current, low voltage, inverter driven motors with current range of
201-2000A (LEM Sensor & MCM LV Inverter):
Connection diagram for medium/high voltage motors with voltage & current transformers (MCM
MV Line):
Connection diagram for medium/high voltage, Aron connected motors (MCM MV Line):
1st Harmonic contents of the selected input channel Display N/A N/A
Harmonic % only
Measurement
phase-neutral 220/277 20 300 350 VAC
voltages (rms)
V1, V2 , V3 100 9 150 175 VAC
Measurement 50/60 45 65 65 Hz
frequency 50/60 25 90 90 Hz
Input power 9 6 12 VA
AC Input voltage 220 85 - 265 VAC
(rms) N, L
Input line 50/60 47 - 64 Hz
frequency
DC Input voltage 310 120 - 375 VDC
N, L