MOTOR CURRENT SIGNATURE

ANALYSIS TEST BY EMPATH

PREFACE

 INTRODUCTION.
 SPECIFICATIONS.
▪ DATA ACQUISITION / SENSORS.
▪ OPERATION TIME.
▪ SOFTWARE.

 PROCEDURE.
 ANALYSIS.
 REPORTS MAKING.
INTRODUCTION
 Motor current data.
 The system supports numerous applications of motor current signature analysis (MCSA) for
predictive maintenance of existing operating systems using electric motors.
 Use of this system is intended to supplement current maintenance practices to improve
equipment life and system availability.
 Single and three phase induction motors are the most widely used motors in industrial and
commercial machinery applications today.
 The larger motors used in industry are three phase 50 Hertz squirrel cage design which are used
to drive pumps, fans, compressors, and a wide variety of machinery.
 When subjected to an increase in load or torque the squirrel cage motor slows slightly and the
supply current increases, resulting in an increase in horse power. Either an increase in torque or a
change in speed will change the motor current, which can be used to sense the load torque or
speed changes.
 Small load fluctuations show up as small motor current fluctuations on top of the 50 Hertz supply
current, and these can be detected with sensitive equipment.
 Because these load fluctuations can be caused by machinery vibrations that result from out of
balance, misalignment, worn gears and belts, friction forces, and reciprocating elements,
detection of the resulting current fluctuations can yield useful machinery diagnostic information.
SPECIFICATIONS:-

 EMPATH hardware interface module “HIM”

 Operating Temperature: 0 - 50C (32 – 122ºF).
 Operating Humidity: 20 - 95% RH (Non-condensing).
 Ports: (3) voltage (3) current (2) straight throuh (BNC)
 A/D conversion hardware : 16 bit, USB
 Controller Card: EMPATH Board
➢ DATA ACQUISITION / SENSORS

 Data Channels: 8 Channels. (user selectable in 2, 4, 8 Ch. mode)

 Channel Functions:
 (3) Channels 1, 3, 5 for Current (3) Channels 2,4, 6 for Voltage (2) Open
Channels for external device connections (± 5.00 V)
 Standard Current Sensors:
 • 20-200 Amp switchable (Qty. 3) • 1000 Amp switchable (Qty. 3) • 600
Amp AC/DC current probe (Qty.1) • 6000 Amp. Flex. Current probes
(optional)
 Input Voltages: External Inputs (+ 5 VAC or VDC)
 Sample Rate: • 48 k samples/sec., (24 kHz freq.) - 2 Ch. Mode • 24 k
samples/sec., (12 kHz freq.) - 4 Ch. Mode • 12 k samples/sec., ( 6 kHz
freq.) - 8 Ch. Mode
▪ OPERATION TIME

 Memory Record: Depends on sampling rate, number of channels

and available hard drive and/or ram memory. Approx. 500 sec.
w/512k RAM.
 Trigger Type: Auto or Manual
▪ SOFTWARE

 Operating System: Microsoft 2000, XP, Vista, Windows-7, Windows-10

 Filtering: Digital (Band Pass, Band Reject, Hi Pass, Lo Pass)
 User-adjustable cutoff frequencies and slopes
 Frequency Analysis: Fast Fourier Transform. (2 & 3 dimensional plots)
 Graphics: Up to 8 plots simultaneously/ overlay, multiple file
compare
 Output: Real-Time Data with Printable Color Graphics
PROCEDURE
➢ CONNECT EMPATH KIT TO EARTH AND ALSO WITH USE OF USB CABLE
CONNECT TO LAPTOP AS SHOWN IN FIGURE.
➢ Attaching the Probes :- CURRENT AND VOLTAGE PROBES SHOULD BE
CONNECTED VERY SAFELY BY ALL SAFETY MEASURES.

 Current probes to be connected to channel nos-1,3 & 5 of kit.

 CTs are connected surround to the bus bar of motors .
 And CTs secondary terminal comes to the MCC (motor control
room) room.
 Where we connect Clampmeter to the R,Y,B phase of secondary
terminals to CT.
 Voltage probes to be connected to channel nos-2,4 & 6 of kit.
 And this probes are connected to the PT from secondary side.
➢ Open Instacal software and select instrument also minimize the deskbar.
The window will be seen as below figure-
➢ Then after open the Empath 7.0 & 7.1. And create new file.
The window will be seen as following figure.
➢ Select the created file.
➢ After selecting created file select the display layout and set the
sensitivity range of current and voltage as shown in following figure-
➢ Next step is to select data file header information and fill motor details
like Power, Speed, Full load current ,CT ratio ,Efficiency, Power factor &
Pole as shown below-
➢ Now select Test information and fill all the data.
Window will be shown as in below figure-
➢ Lastly Enter the Plant details And Press OK. As below figure-
DATA ANALYSIS

 After data have been acquired, both time waveforms and spectral
plots are available for viewing and analysis.
 Multiple plots can be viewed on the same screen.
 The multiple plot technique is especially useful when comparing
phase data, as all three phase currents, or voltages, can be
displayed at the same time as overlays.
 The user’s involvement in data analysis is minimal.
 The “Calculate” button in the Data Analysis mode provides almost
all the information that a user might want.
❑ The window for analysis will be as shown in three different figures below-
 When the “Calculate” button is clicked (right-most button), EMPATH
automatically determines the equipment operating parameters (like motor
running speed, pole pass frequency and slip for an AC induction motor).
 EMPATH uses these parameters plus the data input in the equipment
information (“Header”) to determine what problems exist as evidenced by
the equipment data acquired.
REPORT MAKING
 Report making with this software is very easy and time efficient.
 By pressing the below button you can easily get on site report of motor
tested.
 Word button : Brings up the report on screen in Microsoft Word.
 The printer box sends the report to the printer.

Used to make
reports instantly.
➢ The reports will be like the following images -