Document kind Document identity Revision Instruction 1MZB100400 Owner organization Document type Date of revision (yyyy-mm-dd) Status A Page(s) Motors and Generators Instruction manual for MACHsense-R MSR1600 2017-05-19 Draft 1(31) Division/Department Prepared by Approved by Security level RMMG / PG Service Jan Wallden, Lillemor Rapp, Laxminarayan Daund Henrik Ryegard Confidential Instruction manual for ABB MACHsense-R MSR1600 Reviewed by: Jan Wallden, Lillemor Rapp Approved by: Henr
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 2(31) Contents 1 Introduction ....................................... 4 1.1 General information........................ 4 1.2 Standards......................................... 4 9.1 MFS Location .................................24 1.3 Important note ................................. 4 9.2 Mounting of MFS Sensor .............24 1.4 Limitation of liability ........................
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 3(31) © 2017 ABB Inc. All rights reserved. The contents of this manual are the property of ABB Inc. This documentation is furnished on license and may not be reproduced in whole or in part without the permission of ABB Inc. The content of this manual is for informational use only and is subject to change without notice.
1 Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 4(31) Introduction 1.1 General information This instruction manual contains information on the installation, operation, and maintenance of the ABB MACHsense-R MSR1600. Also referred to MACHsense-R in this manual.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 5(31) To avoid accidents, safety measures and devices required at the installation site must be in accordance with the instructions and regulations stipulated for safety at work.
2 Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 6(31) Recycling and scrapping This product cannot be disposed of as unsorted municipal waste in the European Union. For proper recycling return this product to your supplier or a designated collection point as per your municipal rules. 2.1.1 General The manufacturing process of the machine is carried out in accordance with the Environmental Management System ISO 14001.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 7(31) Polyurethane soft foam (FrenchFoam A-7-146-VP4) · Gasket o Cable gland plate o Top cover plate Copper: Different types of wires/cables used in DAU Polycarbonate sheet: Transparent sheet to shield · PCB: o Main Board o A/C input board o PoE board Carbon Steel Not used Special high quality steel Not used Mixed metallic material Not used Electronic waste The below items should be
3 Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 8(31) Safety Instructions 3.1 Safety precautions These instructions are for all personnel who work on the motor. Personnel performing maintenance on electrical equipment and installations must be certified. The personnel must be trained in, and familiar with, the specific maintenance procedures and tests required for rotating electrical machines.
4 Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 9(31) Important instructions As per Radio Equipment Directive (2014/53/EU minimum separation distance of 20 cm between the user and radiating antenna on MACHsense-R shall be maintained when it is switched on – either in installed or in troubleshooting status. Hazardous voltages and rotating parts can cause shock, burns or other injuries, including death. 4.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 10(31) Attention: FCC et IC Déclaration d'exposition aux radiations RF Déclarations ISDE Cet appareil est conforme aux normes RSS exemptes de licence d'Industrie Canada.
4.2 Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 11(31) Europe compliance Caution: RoHS and REACH Confirmatory Statement The documentation for this device complies with technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances as per EN 50581:2012.
5 Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 12(31) Get started 5.1 · · · · · Quick summary of the MACHsense-R MACHsense-R kit consists of a package of Data Acquisition Unit (DAU) vibration sensors, mounting pads, sensor cables, and installation manual. A web portal is used for showing data. For web address, please contact ABB.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 13(31) 5.3 Preparations for installation 5.3.1 General Adequate planning and preparation results in correct installation, assures safe running conditions and maximum accessibility. During installation, general as well as local safety instructions must be followed. 5.3.
6 Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 14(31) Installing DAU 6.1 Installation kit The MACHsense-R kit contains the following: Item description DAU Accelerometers (four) Mounting pad (four) Cable (four, 10 m each) Installation guidelines The recommended way of installing vibration sensors is to glue the mounting pads into their correct position on the motor.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 15(31) 6.2 Mounting DAU Monitoring device can be mounted on the motor or on neighbouring wall or steel structure depending on the feasibility of the condition. Drilling machine can be used for drilling mounting holes and fixing DAU using suitable bolts. MACHsense-R pictures We reserve all rights in this document and in the information contained therein.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 16(31) DAU Mounting Holes and Space Requirements Small clamp to be welded to the base with 20 mm projection from left and right sides, horizontal hole pitch is 260 mm. Vertical hole pitch is 200 mm when the clamps are aligned 42.5 mm from the top and bottom sides of the baseplate. L bracket to be welded to the base with 12.5 mm projection from the edge.
· Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 17(31) The DAU can also be mounted on the same side as auxiliary terminal box to reduce the cable length for RTD, BTD. - For non-Ex- applications: Cable length up to 500 ft. (150 m) can accurately transmit data from sensors (datasheet) For Ex- applications: Cable length up to 1600 ft.
7 Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 18(31) Installation of Accelerometers (Vibration Measurement) 7.1 Accelerometers Location Accelerometer mounting locations are as follows: · · · · Channel 0 is DS horizontal direction Channel 1 is NDS horizontal direction Channel 2 is DE Axial direction Channel 3 is DS vertical direction When mounting accelerometers, it is important to locate the best positions on the motor.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 19(31) 7.2 Mounting of pads Mounting Adaptor MH130-6A Adhesive Procedure for gluing the pads: 1. All paint must be removed from the surface. Make sure all paint is grinded and the pad is glued directly on the metal on the motor. 2. Clean the surface with recommended cleaner Loctite 7061. 3. After the cleaner has dried, apply glue Loctite AA326 on the mounting pad.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 20(31) Ensure to understand and follow the instructions and information of adhesive and cleaning products for safe and correct use. Make sure to use personal safety equipment and make sure the area is well ventilated. 7.3 Mounting of sensors Mount the accelerometers in the mounting pads by screwing the sensor into the pad. Mounting torque: 2.7 to 6.8 Nm 7.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 21(31) Cable anchoring (Clearance: 6 inches or 150 mm) 4. Use proper conduit and trays wherever required to help cables withstand the operating environment. The sensor cables should be laid away from high voltage cables by distance of at least 250 mm. 5. Connect the shield of the cable to the cable gland for proper ESD protection. 6. Locate X54 Connector on the DAU Board.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 22(31) 7. Ensure proper polarity while connecting the sensor to the DAU Connector Pin polarity DAU Board Connection Sensor protection and wiring must be carried out reliably and in accordance with good engineering practice. The sensor must not be allowed subject to a greater acceleration, or temperature. The sensor location should not hinder other operational and maintenance measures.
8 Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 23(31) Installation in Motors with Fins In some types of motors it might be useful to use other types of mounting pads. One example is motors with cooling fins. Please consult ABB for using these types of pads. One example of pad for motors with cooling fins: 1. Prepare the cooling fins on motor for mounting by scraping or grinding any paint or debris between cooling fins. 2.
9 Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 24(31) Installation of Magnetic Field Sensor (MFS) 9.1 MFS Location The MFS is 3-axis sensor and measures axial, radial and tangential directions. When mounting Magnetic Field Sensor (MFS), it is important to locate the best positions on the motor. Install the MFS sensor with Y as Axial direction i.e. parallel to motor shaft and closer to drive end side of motor. 9.
9.3 Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 25(31) Wiring and Connection of Sensor The sensor cable has 4 connection pairs as below · · · · Vsupply (+5V) & Com X – Axis & GND Y – Axis & GND Z – Axis & GND Locate Connector X54 on the DAU Board and refer following illustration for identifying the MFS Connections.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 26(31) 10 Configuration 10.1 Preparation After installation have been done the MACHsense-R unit needs to be configured: Make sure that the power is switched off before putting in the SIM card. · · Only micro SIM cards can be inserted in the provided hatch. PIN code of the SIM card needs to be disabled. We reserve all rights in this document and in the information contained therein.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 27(31) SIM card holder RJ 45 Ethernet connector 1. First step is to insert SIM card in the SIM card holder. 2. Open the hatch, put in SIM card in correct position and close the hatch. 3. Next step is to connect a computer by using a network cable to connect between Laptop and MACHsense-R RJ45 connector.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 28(31) MACHsense R Installation information ABB MACHsense Company name Serial No: MACHsense R Plant name MAC-address: Drivetrain name Machine name The above filled in information will be used for naming the machine in web portal.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 29(31) Sim card operator (company) Customer Contact persons: Name Email Mobile Phone Number (for SMS notifications) Please provide photos of motor nameplate and all machine including driven object and foundation. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 30(31) 10.2 Commissioning Digitally connect MACHsense-R using the ABB Ability™ MACHsense-R Android app. Log on using your credentials and follow prompts to connect. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Document type Document identity Revision Page(s) Instruction manual for MACHsense-R - MSR1600 1MZB100400 A 31(31) 11 Terms for using ABB MACHsense-R – MSR1600 product/service By registering and using the MACHsense-R portal, you are confirming that ABB will own the collected data and that this data can be used for future product development and that you will comply with all ABB website terms and conditions of use, as well as its Cookies and Privacy Policies.
