This is a photographic template your

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C441 Motor Insight

Overload & Monitoring Relay

2008 Eaton Corporation. All rights reserved.

Motor Insights
Advanced Overloads

Motor Insight (1-540 amps)

Reduccin del costo de mantenimiento con la carga bajo control y diagnstico
especfico en tiempo real
Rpida configuracin datos de cargas asociadas y datos de proteccin.
Capacidad de monitoreo de corrientes, voltages y potencias.
Mdulos de comunicacin mltiples con disposicin de E / S

Motor Insights
Performance

Motor Insight
Advanced Monitoring
Advanced Protection
Communications
1 - 540A FLA, 240-600VAC

Motor, Load, & Line Protection / Monitoring

IT.
Solid-State OLR
Communicating
0.25 - 400A

Motor Protection

C396 - Standard

C440

Solid State OLR

0.1 - 1500A

Freedom C306
Thermal OLR
0.25 - 1500A

XT
Thermal OLR
IEC only
0.1 - 630A

Price
3

Motor Insights C441

8 Unidades Basicas:
(170-264V line power)
1-90A sin CTs externos
90-540A con CTs externos

(323-528V line power)

1-90A sin CTs externos
90-540A con CTs externos

89-660V line power)

1-90A sin CTs externos
90-540A con CTs externos

(93.5-132 control power)

1-90A sin CTs externos
90-540A con CTs externos

Certifications
UL, CSA, CE, RoHS

Modulos de comunicacion:
Modbus (con y sin I/O)
DeviceNet con I/O
Profibus con I/O
Ethernet IP (Mid 2010)

Display remoto
Type 1, 12 and 3R
NEMA 3R

Motor Protection
Thermal Overload (Sobrecarga Termica)

Definition: Sobrecarga trmica es una condicin en la que el consumo

de corriente de un motor supera el 115% de la corriente nominal de
carga para un motor de induccin
Causas:

Consecuencias:

Un suministro a tensin reducida al motor causara que la corriente se

eleve para mantener la potencia necesaria
Aumento de consumo en la carga o torque que esta impulsado por el
motor.
Un mal factor de potencia causara sobre consumo de corriente.

Aumento en el consumo de corriente, sobrecalentamiento de cables y

ruptura del aislamiento, que puede causar un fallo del sistema. Adems,
un aumento en la corriente puede aumentar el consumo de energa
excesivamente y afectar en la facturacin.

Motor Insights Capacidad Protectora

Trip class 5-30

1-90 amp FLA sin CTs externos (540 amp FLA con CTs externos)
Monitoreo FP y Proteccion de bajo voltage.
5

Motor Protection

Motor Protection
Mechanical Jam (Salto de Carga)

Definicin: Mechanial Jam es similar a la sobrecarga trmica dado que

es un consumo de corriente en el motor encima de las condiciones
normales de operacin

Causas:

Consecuencias:

Atasco mecnico, interferencias, bloqueos, o el atoramiento de la carga

del motor o el motor
Condiciones anormales de operacin y perdida de aislacion.

Motor Insights Capacidad Protectora

Proporciona un setting configurable que se activa durante el "estado de

funcionamiento del motor," para evitar disparos inconvenientes

Umbral de disparo 150 a 400% de FLA, o OFF

Retardos configurables de 1-20 segundos

Motor Protection
Ground Fault (Falla Tierra)

Definicin: Una linea se fuga a tierra

Causa:

Consecuencias:

Perdida de aislacion, descargas parciales, una corriente L1 L2 L3 se

fuga tierra
Una falla a tierra puede conducir a una falla del motor, daos a la
integridad del equipo.

Motor Insights Capacidad Protectora

Capacidad de proteccin de falla a tierra hasta 0,15 amperios

En el caso de un GF, Motor Insight puede alarmar o disparar un rel
alternativa que se puede utilizar para activar el interruptor o encender
una luz de advertencia
Corriente de falla a tierra tambin puede ser monitoreado en tiempo real
Configurable Trip Delay 1-20 seconds, but based on GF level

Motor Protection
Unbalanced Phase Currents (Desbalance de corrientes)

Definicion: Diferencia de la corriente entre las fases en un sistema

trifsico
Causa:

Consecuencias:

Cuando una carga trifsica es alimentado con una lnea de baja calidad,
la tensin por fase puede ser desequilibrada causando corriente
desequilibrada
Cuando hay una fuga de corriente de fase a fase
Las corrientes desequilibradas pueden conducir a los bobinados del
estator del motor que se sobrecarguen, causando un calentamiento
excesivo, la reduccin de la eficiencia del motor y la reduccin de la
vida de aislamiento

Motor Insights Capacidad Protectora

Ajuste de proteccin de desequilibrio de corriente (de 1 hasta 30.1%, o

como OFF) y monitoreo en tiempo real
Ajustes de desequilibio de voltages (1.20% en el modo de alarma,
1.20% como OFF o en modo de disparo) y monitoreo en tiempo real
Retardo de disparo configurable 1-20 segundos
9

Motor Protection
Phase Loss - Current (single-phasing) (Perdida de fase)

Definition: Una de las tres fases se pierde

Source:

Consecuencias:

Multiple causas: no alambrado, alambrado mal realizo, fase a tierra,

fusible abierto, etc.
Puede conducir a vibraciones del motor no deseados adems de
provocar fases desequilibradas.

Motor Insights Capacidad Protectora

Motor Insight tiene un ajuste de fallo de la proteccin cuando el motor

de arranque vee que una de las fases desciende por debajo de 60% de
las otras dos fases

Retardo de disparo configurable 1-20 segundos

10

10

Motor Protection
Phase Rotation (phase-reversal) (Secuencia de fases negativa)

Definicion: Cableado incorrecto

Causas:

Motor mal conectado

Alimentacion mal conectada

Resultado:

Puede provocar accionamiento del sentido de giro del motor en la

direccion incorrecta

Posible falla mecnica y / o lesiones a un operador

Motor Insights Capacidad Protectora

Ajuste de fallo de proteccin configurable, lo que permite al usuario

definir la secuenciacin en fase destinada a tal aplicacin

Setting 1 ABC, Setting 2 ACB, OFF

NO TRIP DELAY
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Load Protection
Undercurrent & Low Power (Baja corriente y Perdida de
Potencia)

Definicion: Potencia media RMS actual suministrada al motor cae por

debajo de las condiciones normales de funcionamiento
Causa:

Resultado:

Una parte de la carga del usuario desaparece, causada por una correa
rota, una bomba en seco (baja carga de succin), o una bomba
centrfuga-fuera.
Puede causar un calentamiento excesivo, daos en los sellos y romper
las condiciones normales de operacin deseadas.

Motor Insights Capacidad Protectora

Baja corriente (Ajustable 10-90% de FLA, OFF)

Configurable trip delays 1-60 seconds

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12

Load Protection
High Power (Alta Potencia)

Definicin: La carga del motor est atrayendo ms potencia de lo

esperado en condiciones normales de funcionamiento

Resultado:

Si una falla de alta potencia no se detecta puede ser que el resultado

del proceso no cumpla con las especificaciones

Motor Insights Capacidad Protectora

La potencia puede ser monitoreada en tiempo real

Configurable trip delay 1-60 seconds

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Line Protection
Over voltage (Sobre Voltage)

Definicin: Cuando el voltaje de la lnea al motor excede lo tensin

nominal

Causa:

Mala calidad de la lnea

Resultado:

Mal funcionamiento

Se recomienda un lmite de disparo de 110% de la tensin nominal

Motor Insights Capacidad Protectora

Over-voltage protective settings, up to maximum range of device

Todos los fallos relacionados con overvoltage tienen un modo "alarma

trip"

Configurable delay 1-20 seconds

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Line Protection
Under voltage (Bajo Voltage)

Definicion: Cuando el voltaje de la lnea al motor est por debajo de la

tension nominal

Source:

Resultado:

Mala calidad de la linea

Consumo de corriente excesivo. Esto aumenta el calentamiento de los
devanados del motor y se puede acortar la vida del aislamiento. Se
recomienda un lmite de disparo establecido en el 90% de la tensin
nominal

Motor Insights Capacidad Protectora

Under-voltage protective settings, down to minimum of device range

Todos los fallos relacionados con overvoltage tienen un modo "alarma

trip"

Configurable delay 1-20 seconds

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15

Line Protection
Unbalanced Voltage (Desbalance de Voltages)

Definicion:

Tensin desigual entre las fases en un sistema

trifsico

Causa:
Cuando una carga trifsica es alimentado con una lnea de baja
calidad, la tensin por fase puede ser desequilibrado..

Resultado:
Tensin desequilibrada provoca corrientes de desequilibrio,
que conducen a los bobinados del estator del motor a
sobrecargas, provocando un calentamiento excesivo, reduccin
de la eficiencia del motor y reduccin de la vida de aislamiento

Motor Insights Capacidad Protectora

Voltage Unbalance ajustable 1-20%, OFF
Monitoreo en tiempo real
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Motor Insights
El Motor Insight, el primer producto inteligente de
la familia de soluciones de control de energa de
Eaton, es un dispositivo de proteccin del motor,
carga y lnea altamente configurable con
supervisin de la alimentacin, el diagnstico y las
comunicaciones flexibles le permite al cliente
ahorrar energa, optimizar su programa de
mantenimiento, y configuracin de mayor
proteccin del sistema que extiende la vida del
equipo, lo que reduce los costos generales y el
tiempo de inactividad
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17

Motor Insight Exitos Ahorro de Energia

Control Engineering
Scenario:

Three 480V 75 hp, 96 amp tripping-current motors at Indiana Ave lift station

Customer was previously only monitoring flow to detect problems

Flow was the same for all three pumps, however with Motor Insight they
observed pump 3 drawing abnormal current due to a foreign object on the
impeller
Motor Insight - Value Add:

ENERGY SAVINGS

Motor Insights advanced

monitoring capability and flexible
communications capability allowed
the plant to observe this abnormal
operation in real-time

Motor 1

Motor 2

Motor 3

Draws 60
amps

Draws 60
amps

Draws 90
amps

They sent maintenance personnel

immediately upon observation and
removed the foreign object

sqrt 3*14.4 kW*$0.10/kW-hr *24 hours/day*7 days/weeks*26 weeks/year

= $10,894 of wasted energy

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18

Motor Insight Exitos Optimizacion de Mantencin

Control Engineering
Pre Motor Insight Maintenance Practice:

Limited operational information required weekly inspections of motors and pumps in hard to
access areas 30 FEET DOWN!

Inspection required 2 personnel due to OSHA regulations

Listened to operating noise

No pre-notion of problems that could be occurring, so individual may be over or underqualified for issue at hand

No pre-notion of problems that could be occurring, so tools at site may be inappropriate

thus requiring multiple trips to site

Motor Insight Value Add:

MAINTENANCE OPTIMIZATION

Eliminating Unnecessary Inspections: Knowledge of real-time data along with 10 history fault-queue enables for
sending personnel only when data from Motor Insight indicates an issue

Optimizing Labor Skill Sets: Understanding of fault-type allows for appropriate maintenance personnel selection.
Having the right man for the job enables the plant to better utilize skill sets reducing wage rates per service trip I.e. dont send
your 40-year maintenance person to clear a clog

Reducing Service Time: Understanding of fault-type allows for proper tool selection before heading to site, avoiding
costly second trips and reducing service time

Pre-Motor Insight:
50 service trips/year * 2 labor heads * $40/hr * 2 hours/service trip = $8,000/yr
Post-Motor Insight:

15 service trips a year * 2 labor heads * $30/hr * 1 hour/service trip = $900/yr

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19

Motor Insight Exitos Aumento Vida Util de Equipos

Control Engineering
Scenario 2:

A centrifugal pump is pumping against a mostly closed valve. The pump continues to run
because the float limit switch is not dropping as the water level is not decreasing. A second
pump is turned on to compensate, thus two pumps are running and are performing the work of
essentially one pump

Pre-Motor Insight:

Both pumps continue to run in parallel wasting valuable energy

Pump 1 is running unnecessarily, since it is doing almost no real work, and thus putting
unneeded hours of operation on the pump and the motor, wearing out bearings
The dead-headed pump 1 continues to run and heats-up quickly, heat-aging the pump-seal
thus decreasing the life of the pump

Motor Insight Value - Add: EXTEND EQUIPMENT LIFE & REDUCE DOWNTIME

Reduction of wasted run-time hours: Due to the protective-fault feature called Under Power Motor Insight faulted
Motor 1 taking it offline (A centrifugal pump goes to low power in a dead-headed scenario). Pump 2 came online and
completed the pumping activity. Pump 1 was saved from doing non value-add work, extending the life of the bearings

Reduction of wear on components: Motor Insights advanced protection offering ensured that the seal on Pump 1
did not heat up and therefore did not heat-age, thus the product life is extended

Motor Insight has 12 protective faults and the ability to monitor in real time, providing Motor, Load and Line protection

In this Scenario one of the Load protective settings, Low Power, prevented the heat-aging of the seal

Pump 1s seal would have cost $1,000 to replace

Two motors running to do the work of one wastes additional energy, $????
Reduction in maintenance frequency due to extended life, $????
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20

Caracteristicas Genericas

Altamente configurable tanto en

protecciones
y monitoreo
de
variables

Slow acceleration program

10 Monitoring Choices

Confiabilidad

Enhanced surge and sag withstand capacity

Robust design suited for applications with

high line conditions and poor power quality

Comunicacion Flexible

Multiple communication modules

Can use the communications module

and remote display at the same time

Terminal Block

Fault trip and reset behavior configurable by

fault type

Seguridad

Optional Remote Display

IP20 rated terminal block

Terminal blocks are set back from the
display to reduce operator shock hazard
Allows for configuration from outside of
the panel

Facil uso

Bright LED display with easy to

understand settings and references
Type 1 Remote display has the same
user interface as the base unit device
Adjustments to overload settings can be
made without disconnecting power
Line-powered design

Mejor Diagnosticos

10 fault queue available locally

Local interface and monitoring

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Proteccin Configurable

Motor Protection

Cada
falla
configurables

Alarmas disponbles para lineas

y condiciones de falla a tierra

tiene

ajustes

Jam (100-400% of FLA)

Current Unbalance (1-30%)
Current Phase Loss (60% fixed)
Ground Fault Current (as low as 0.15 A)*

Motor,
Load, line
Protection
Thresholds

Phase Reversal (ignore, ABC, ACB)

Load Protection
Under-Current (10-90% of FLA)
Low Power (kW) (lowest power in range)

High Power (kW) (highest power in range)

Line Protection
Over voltage (170-660V)
Under voltage (170-660V)
Voltage Imbalance (1-20%)

*not all applications can achieve this

low level GF 22

22

Configuracion ciclos de partida

Aceleracion Lenta

Altas cargas en inercia, cuando parten pueden causar disparos inconvenientes

no deseados conduce a arranques fallidos

Transient state
without
configurable start
cycle, start-up can
be impossible

Run transition set point 25-125% of FLA

Run transition time 1-180 seconds

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Sistema de Monitoreo
Monitoreo de.
Current Per Phase and Average RMS

Start saving time and money by

knowing in real time what is
happening at your load

Conserve energy

Optimize
your
maintenance

Set alarm conditions

Current Unbalance Percent*

Ground Fault Current*
Voltage Per Phase and Average RMS
Voltage Unbalance Percent*

preventive

Power

Power Factor*
Frequency*
Motor Run Hours*
Thermal Capacity
*Available in Advanced Configuration menu
*When using communications additional data is available

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24

Comunicaciones Flexibles

Communication
Port

Modbus Module

DeviceNet +
I/O Module

Remote Display Port

Remote Display and Communication

Modules can be used at the same time
unlike competitive devices

Modbus (+ I/O 120 VAC & 24VDC)

DeviceNet + I/O 120 VAC & 24VDC

Profibus + I/O 120 VAC & 24VDC

I/O has 4 digital inputs and 2 outputs

Snap-on modules provide flexibility in

communications options
25

25

Diagnosticos
F.14 is a Jam Fault, No Deciphering of
Fault Codes is Needed!
Motor Insight stores the last 10 faults (best in class) in a

Diagnostics

non-volatile memory

The fault queue is available locally, through the remote

display, and through communications

All protection faults do not need to be interpreted

During a fault the LEDs jump to the cause of the fault, so

no interpretaion of the fault code is needed.

An example would be if a Jam fault occurred, the display

will show F.14, but simultaneously the LEDs jump to
highlight the Protection Menu, and the Jam Trip % setting
letting the user immediately know that F.14 is a Jam Trip
fault

Full word descriptions with units on the user interface

makes interpretation and setup a breeze

More Diagnostics Available with Motor Insight HMi

Time-stamping faults

Recording more than the last ten faults

Waveform capture when a fault occurs

The ability to look at waveforms in real time

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Capacidad de diagnstico limitada

Bi-metal and Electronic Overload Relays
- Fault Indications
Possible Cause
Thermal Overload
Thermal Overload Trip Only
(note: electronic overloads can trip for current
unbalance and single phasing, however there is no
separate indication, so all faults appear as thermal
overload)

Possible Cause of the Possible Cause

Worn motor bearings
Worn pump bushings
Increase in motor load
Undersized motor
Jam
Mechanical interference with motor
Mechanical interference with driven load
Current Unbalance
Phase-to-phase leakage path
Unbalanced voltage from poor line quality
Single-Phasing
Loose wire
Improper motor wiring
Grounded phase
Open fuse
Voltage Unbalance
Poor incoming line quality
Under Voltage
Poor incoming line quality
High Power
Dead-head positive displacement pump
Change in process materials
Ground Fault
Line to ground leakage path
Number of Inspections required if using a bi-metal or electronic overload =

This chart demonstrates the amount of inspections that have to take place in order
to find the root cause of a thermal overload trip when using a Bi-Metal or an
Electronic Overload

As you can see, for a Thermal Overload trip there could be 17 different root
causes, meaning the user has to check 17 aspects of their system

If they dont find the true root cause, the failure will occur over and over leading to
unscheduled downtime and loss of productivity
27

Number of
Possibilities
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17

27

Diagnosticos disponiblen mejoran la

productividad y ganacias.
Motor Insight - Fault Indications
Thermal Overload

Possible Cause
Worn motor bearings
Worn pump bushings
Increase in motor load
Undersized motor
Loose wire
Improper motor wiring
Grounded phase
Open fuse
Mechanical interference with motor
Mechanical interference with driven load
Phase-to-phase leakage path
Unbalanced voltage from poor line quality
Line to ground leakage path
Dead-head positive displacement pump
Change in process material properties
Poor incoming line quality
Poor incoming line quality
Poor incoming line quality
A mis-wired motor
Inadvertent phase reversal by the utility
Change in the load: broken belt, low suction head, dead-headed centrifugal pump
Rise in line voltage
Change in the load: broken belt, low suction head, dead-headed centrifugal pump
Average number of inspections required if using a Motor Insight Overload and Monitoring Relay =

Single Phasing

Jam Trip
Current Unbalance
Ground Fault
High Power
Under Voltage
Voltage Unbalance
Over Voltage
Phase Rotation
Under Current
Under Power

Number of
Possibilities

Due to Motor Insights numerous fault indications, the user can eliminate the
majority of possible causes

This reduces the average number of inspection points from 17 to ~2

Motor Insight also provides fault indications for faults that do not lead to higher
currents, giving you more information about your Load and Line
28

4
2
2
1
2
1
1
1
2
2
1
1.92

28

Enfoque a la seguridad
Finger Proof

IP20 rated terminal blocks

Terminal blocks are recessed

away from operator interface
recessed
Competitive Voltage
Terminals Allow for
wire to reach the
user interface

Motor Insights Voltage

Terminals are recessed
behind the user interface
and are IP-20 rated
(finger proof)

Arc Flash Safety

Optional remote display or the Motor Insight

HMi allow for all configuration and
troubleshooting to be done from outside of
the panel, keeping the door between the
operator and power components
29

29

Facl uso y programacin

Interfaz de usuario

Intuitive, easy to configure

Parameters, monitoring output, and units clearly

described, unlike competitive offerings

Adjustments can be made without disconnecting

power

Bright LED display works at very low temperatures

10 event fault history

Remote Display/HMi

RD same as the base unit, just plug it into the base

unit and it takes control

Unlike competitive devices, no external power supply

is needed and doesnt interfere with communications

Remote Display rated NEMA type 1, 12, and with a

kit, 3R

HMi application available for MCC applications

Terminaes adicionalesI/O

Two terminals provided for each phase input for easy

connection to CPT

Isolated 120 VAC Reset Input

B300 Ground Fault Relay Output

Form C Fault Relay includes 2 common terminals

Wide openings capture wire easily

30

30

Codigos
Reduced Inventory

6 styles achieve FLAs from 1540 amps and Voltages from

170-660 VAC.
Meter, overload relay, GF relay,
pump-off controller, reset
timers, I/O all in one package!
Saves on stocking costs and
installation time

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Objetivo y Aplicaciones
Dadas las capacidades de configuracin avanzada de Motor Insight tanto
en monitoreo, comunicaciones y caractersticas de proteccin se orienta a
cargas y motores crticos dentro del proceso

Target Markets

Oil & Gas/Irrigation

Water & Wastewater
Mining
Metals Processing
Industrial / Continuous
Process
Campuses
Pulp & Paper
Heavy Machinery
EASA Shops

Applications

Coal Bed Methane Wells

Submersible Pumps
Centrifugal Pumps
Belt/Chain Driven Loads
Low Speed Mixers
Remote Loads in hard to
access areas
Rail grinders/rock crushers
Previously failed motors to
help with diagnostics
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32

C441 Seleccion
Motor Insight Voltage and Current Range Selection using Tables 3 and 4 from the
Catalog, CA042090001E

Scenario 1: 480V, Motor FLA is 30 amps

Selection 1: C441CB, the C represents
voltages from 323-528, and the B
represents the 20-90 amp internal CTs
Scenario 2: 525V, Motor FLA is 300 amps
Selection 2: C441DA, the D represents
voltages from 489-660, and the A
represents the 2-9 amp internal CTs

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This is a photographic template your

photograph should fit precisely within this rectangle.

Preguntas?

2008 Eaton Corporation. All rights reserved.

Resumen
Tres beneficios y ventajas de MotorInsight?
Mejor Diagnostico, Extension Vida Util, Ahorro de Energia,
Optimizacion de Mantencion

Tres tipos de reles de sobrecarga?

Bi-metal, solid-state/electronic, advanced

Que protocolos de comunicacion se puede integrar

con MotorInsight?
Modbus, DeviceNet, Profibus, and Ethernet IP is coming

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35

Motor Insight Overload and

Monitoring Relay Demo Exercise
Wiring:

Wire the power cord to the power supply

White L
Black N
Green Ground
Wire the Motor Insight to the 24V power
supply

Navigating the Device:

The intent is that the device is intuitive
enough that no directions are necessary
MODE/CANCEL
moves the top indicating LED
through the 3 menus, protection,
operation, and monitor
UP/DOWN ARROWS
scrolls through the given menu
that the top indicating LED is
lighting
when editing, scrolls through
available settings
EDIT/SAVE
when configuring in the
Protection or Operation menu,
press once to edit, once the
setting starts blinking scroll with
arrows, then press again to save

Demo Exercise 1- Configure Jam:

Press the MODE button until the
Monitor LED is lit.
Scroll through Amps, Volts, Power,
Thermal Capacity, using the
UP/DOWN arrows
Press the MODE button once to light
the Protection LED
Press the UP/DOWN arrows until the
LED for Jam Trip is lit.
Press EDIT/SAVE, the display
should be blinking indicating editing
Use the UP/DOWN keys to set Jam
Trip % to 300
Press EDIT/SAVE to save this
setting
Repeat with other settings
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Motor Insight Overload and

Monitoring Relay Demo Exercise 2
Demo Exercise 2 Simulate Under
Power Load Fault:

Press the MODE button until the Monitor

LED is lit
Use the UP/DOWN arrows to note the KW
reading (you will need this value later)
Press the MODE button once to move to
the Protection menu
Press the DOWN arrow until the Low Power
LED is lit

Press the EDIT/SAVE button

Use the UP/DOWN arrows to find a
KW value higher than what was noted
earlier when you noted KW to the
motor. Once set, this will trigger a
fault
Press the EDIT/SAVE button to store
this value as your Low Power
threshold and then quickly press the
mode button to move to the next
menu
You will shortly (5 seconds) see a trip
caused by the power in the simulation
being under the threshold you just set
Note both the fault code (F.15) AND
the LED for Low Power is lit up, thus
no need to interpret fault codes, as
long as it is a protection type fault the
LED will be lit

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Configuracin Tipica

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38

Conexin de CTs - Interpretacin

39

39

Conexin de CTs - Interpretacin

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40

This is a photographic template your

photograph should fit precisely within this rectangle.

Preguntas?

2008 Eaton Corporation. All rights reserved.