K6CM explanatory material

“Motor Condition Monitoring”

OMRON corporation
Components Div.
Timer & Monitoring Relay PMG

© OMRON Corporation
CONFIDENTIALB
CONFIDENTIAL © OMRON Corporation 0
 Application case of Motor Condition Monitoring
Automotive factory : Automotive parts/ Food industries
Assembling/Press etc. Dryer motor for Glass/Food etc.

Infrastructure/Factory facilities :
Big motors for Conveyor
Air-conditioning fan motor/Water service pump etc.

CONFIDENTIALB © OMRON Corporation 1

 Machine Maintenance situation & Omron solution
Maintenance engineers routine 3-phase
Induction motor
1. Visit machine

3. Fixing/
Repair/Replace 2. Check several parts

Human operation Human & Machine

CONFIDENTIALB © OMRON Corporation 2
 Motor Condition Monitoring : Type K6CM (3 types : 6 models)

AC200-480V
3-phase
Induction motor ZCT CT
AC100-
Vibration/Temp. 240V
All-in-one
Sensor head
or
DC24V
Insulation resistance
Vibration & temp. (Elelectrical leakage
Current Analysis
Pre Amplifier

In
control
Data panel
Storage

Setting &
Simple PLC
monitor
Software

Alarm output
© OMRON(x3) Alarm output (x3) Alarm output (x3)
CONFIDENTIALB Corporation 3
3
 Type K6CM (3 types : 6 models) and Sensors
Motor Condition Monitoring : K6CM series Dec./2017 release (plan)
Controllers (AC input or DC Input)
Model Type
K6CM-CI Current Analysis
K6CM-IS Insulation resistance
K6CM-VB Vibration & temp.

Vibration/Temp.
All-in-one Sensor ZCT CT
Sensors
Model K6CM Type
K6CM-CICB005 5A
K6CM-CICB025 25A
K6CM-CICB100 100A
Current Analysis
K6CM-CICB200 200A
Vibration/Temp. Sensor for Sensor for
K6CM-CICB400 400A All-in-one Insulation resistance Current Analysis
K6CM-CICB600 600A Sensor head (Clamp type) (Clamp type)
+ Pre Amplifier
K6CM-ISZBI52 φ52 (300A) Insulation resistance
Sensing range Sensing range
K6CM-VBS1 Vibration & temp.
Frequency：～10kHz Insulation resistance：0～1.000MΩ
Acceleration：(0.5)～9.99G Leakage current：0～200.0mA
CONFIDENTIALB © OMRON Corporation Velocity：(0.5)～45m/s * 7.5kW motor max. 4
 Overview of K6CM attached Software for PC

Motor Condition Monitoring for daily maintenance

Motor Status Monitor Alarm Event History Trend Graph
Display multiple motor current status Display multiple motor Alarm Event Display Motor Condition (Motor
(liken a Healthy, Need maintenance History vibration, Temperate, Insulation
and alarm so on) resistance and Current analysis)

K6CM Parameter setting Export CSV data

Set Monitoring Trigger
Measured Data
Register Motor Information
Alarm Event History
Ethernet/IP setting
Adjust Alarm Threshold K6CM Etc.

attached software
Ethernet/IP

CONFIDENTIALB © OMRON Corporation 5

 Motor Condition Monitoring : K6CM Product overview

Multi-sensing & original diagnostic algorism

W45mm×H90mm×D86mm
Control panel Minimize the opportunity loss
Monitor the value and
checked if there is any errors.
(skill free maintenance)
Electromagnetic
contactor
or Digitalization of know-how
Inverter PC OS: PLC TP
Windows
CT
(Current)
Concentrated monitoring &
Graphing & data logging remote monitoring
ZCT
(insulation resistance)

Efficiency improvement of routine inspection

Pre-
AC200-480V 600A Max.
Amplifier
(7.5kW motor Max. for
Alarm informs that the
Vibration/temp. Insulation resistance) monitoring data exceeds a set
Sensor 3-phase induction motor threshold value.
CONFIDENTIALB © OMRON Corporation 6
 K6CM Application Guide
“Motor Condition Monitoring”

OMRON corporation
Components Div.
Timer & Monitoring Relay PMG

© OMRON Corporation
CONFIDENTIALB
CONFIDENTIAL © OMRON Corporation 7
 K6CM is for motor aging degradation monitoring
For 3-phase Induction motor, No Servo motor
Water pump etc.

Monitoring motor condition Can not monitor

Every hour/day/week/month etc. msec order

1sec
CONFIDENTIALB © OMRON Corporation 8
 Kind of motor/applicable
Kind of Motor View K6CM
3phase-induction Conductor + Motor
motors

Invertor + Motor
Inverter motors

spindle motor
Gear, spindle
OK: Inverter type Motor
NG: Servo motor
type
Single phase motors Single phase AC power
Motor

Servo motors Motor

Amplifire

Stepping motor
Stepping Motor
CONFIDENTIALB © OMRON Corporation 9
 K6CM has no big memory IC

K6CM PC Tool

Up to 10 motors

or
NJ/NX Function Block
for K6CM

CONFIDENTIALB © OMRON Corporation 10

 Example of Motor structure and Failure mode

> Rotor break

Rotor
The rotor is the
> Bearing break
part of the motor
> Bearing scratch
that rotates
> Inadequately-lubricated
Bearing
Rotary shaft Reduce wear on rotating
Power transmission parts(expendables)
to Load side There are two bearings
in the motor
Motor burn out
> Stator break
> Electrical > Insulation aging
leakage Stator
Generates the force
to turn the rotor

CONFIDENTIALB © OMRON Corporation 11

 Example of Motor system and Failure mode

Invertor or
Electromagnetic > Phase loss K8DT series
contactor
> Reverse phase

>Misalignment
> Imbalance > Motor failure

K6CM
3-phase Vibration & temp.
Coupling
Induction motor For Bearing failure
> Overload (Joint)

Load side
(Ex. Blower fan) K6CM
Current Analysis

* The K6CM “Current Analysis” can be detected both Motor failure and Load side abnormal condition.
CONFIDENTIALB
But it can not be defined which motor or load side might have problem.
© OMRON Corporation 12
 K6CM monitoring time and monitoring trigger timing
* Vibration data should be measured same motor speed.
Motor
Revolution Current Vibration
Analysis & Temp.
Min. 5sec Min. 0.5sec

Min. 5sec Min. 0.5sec

Motor Motor Constant Motor Constant Motor Motor Motor Constant Motor Constant
Stop Speed Speed-1 Speed Speed-2 Slow down Stop Speed Speed-1 Speed Speed-2
Up-1 Up-2 Up-1 Up-2

Monitoring condition :10 sec (without Invertor)

60 sec (with Invertor)
Insulation resistance

CONFIDENTIALB © OMRON Corporation 13

 K6CM Display & PC data logging timing (normal mode)

Motor Revolution

K6CM Monitoring sampling cycle : every xx sec

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

K6CM LCD Display value change by every sampling cycle

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Regular PC data update (when logging time is 1 min)

1 min 1 min 1 min

Data No.6 Data No.12 Data No.18

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 K6CM Display & PC data logging timing (trigger mode)

Motor Revolution
Trigger signal Trigger signal Trigger signal Trigger signal

K6CM Monitoring sampling cycle : every xx sec

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

K6CM LCD Display value change by every trigger signal input

3 9 14 18

Regular PC data update (when logging time is 1 min)

1 min 1 min 1 min

Data No.3 Data No.9 Data No.18

CONFIDENTIALB © OMRON Corporation 15
 Comparison table each K6CM types

Sensor Monitoring target Without With Invertor Monitoring Monitori

Mountin Invertor ng
g Motor
Motor Motor Monitor Monitor Monitori Timing Rotating Time
body Load ng Data speed

Current Clampin Baring/ Can Possible Possible Bigger Constant No Min. Depend
Analysis g motor Rotor/St monitor than speed influenc 5sec on CT
wire ator without e type
trouble Invertor

Vibration Screwing Baring Can not Possible Possible Bigger Constant Influenc Min. No
motor trouble monitor than speed e for 0.5sec conditio
body without monitori n
Invertor ng data

Insulation Clampin Insulatio Can not Possible Possible Similar Motor No Min. Up to
resistance g motor n aging monitor as running influenc 10sec. 7.5kW
wire without e or
Invertor 60sec.

CONFIDENTIALB © OMRON Corporation 16

 Motor System Failure mode and Motor Condition
Human can feel …
Human can not feel (abnormal noise,
abnormal vibration so on)

Load trouble Overload Overload Overload

Normal Load
(overload so on) (Small) (Middle) (Heavy)
Load
side
Coupling (Joint)
Misalignment
Load side trouble may give damage for
Motor bearing (scratch)
Rotor/Stator
trouble
Inside
Motor Bearing Bearing Bearing
Bearing Dried
Scratch Scratch Scratch
trouble Grease
(Small) (Middle) (Large)

Good Motor condition Time path Motor Failure

CONFIDENTIALB © OMRON Corporation 17
 Motor System Failure mode and K6CM type
Human can feel …
Human can not feel (abnormal noise,
abnormal vibration so on)
Current Analysis

Load trouble Overload Overload Overload

Normal Load
(overload so on) (Small) (Middle) (Heavy)
Load
side
Coupling (Joint)
Misalignment

Rotor/Stator
trouble
Inside
Motor Bearing Bearing Bearing
Bearing Dried
Scratch Scratch Scratch
trouble Grease
(Small) (Middle) (Large)

Insulation Vibration
resistance
Good Motor condition Time path Motor Failure
CONFIDENTIALB © OMRON Corporation 18
 How to use K6CM-CIM
“Current Analysis” type

© OMRON Corporation
CONFIDENTIALB
CONFIDENTIAL © OMRON Corporation 19
 K6CM Current Analysis basic principle
3-phase induction
current
motor(3-wire)
not connected to the motor
motor load
N

earth

(1). Healthy Motor current wave

“PURE” sine current wave

Smooth rotation

(2). Unhealthy Motor current wave several “NOISE” on sine current wave

Abnormal
vibration
CONFIDENTIALB © OMRON Corporation 20
 Choose CT and install

Invertor Conductor
2 types of input voltage
100-240VAC
24VAC/DC or

CT

You can clamp CT for

any 1 wire of motor cable

* Clamp type CT
Permissible attachment/removal frequency : up to 100 times
CONFIDENTIALB © OMRON Corporation 21
 How to calculate “Motor Ampere” to choose CT

Motor Power (kW)× 1,000

Motor Ampere (A) =
Motor Power
× Voltage (V) × Factor (0.9) × Efficiency (0.8)

Recommendation Motor Recommendation Motor

CT Model CT Tolerance
(AC200V) (AC400V)
K6CM-CICB005 5A from 1.00A to 5.25A 0.75kW from 1.5kW to 2.2kW
K6CM-CICB025 25A from 5.00A to 26.25A from 1.5kW to 5.5kW from 3.7kW to 11kW
K6CM-CICB100 100A from 20A to 105A from 7.5kW to 22kW from 15kW to 45kW
K6CM-CICB200 200A from 40A to 210A from 30kW to 45kW from 55kW to 90kW
K6CM-CICB400 400A from 80A to 420A from 55kW to 90kW from 110kW to 200kW Clamp type CT for
K6CM-CICB600 600A from 120A to 630A from 110kW to 150kW from 250kW to 300kW
K6CM Current Analysis

Motor current might be almost half of calculated ampere without motor load.
Hence “CT” should be detected from 50% through 100% of calculated motor ampere.
CONFIDENTIALB © OMRON Corporation 22
 Ref. CT selection table for AC200V motor

K6CM-CICB005 1～5A CT Model & CT Tolerance

K6CM-CICB025 5～25A
K6CM-CICB100 20～100A
0.75kW(2.0～3.0A)
2.2kW(5.8～8.8A) K6CM-CICB200 40～200A
3.7kW(9.8～14.8A)
K6CM-CICB400 80～400A
5.5kW(14.6～22.1A)
7.5kW(20～30A) K6CM-CICB600 120～600A
11kW(29～44A)
15kW(40～60A)
18.5kW(49～74A)
22kW(58～88A)
30kW(79～120A)
37kW(98～148A)
Motor Power & Motor Current 45kW(119～180A)
55kW(145～220A)
75kW(199～301A)
90kW(238～361A)
110kW(291～441A)
132kW(349～529A)

CONFIDENTIALB © OMRON Corporation 23

 Ref. CT selection table for AC400V motor
CT Model & CT Tolerance
K6CM-CICB005 1～5A
K6CM-CICB025 5～25A
1.5kW(2.0～3.0A) K6CM-CICB100 20～100A
2.2kW(2.9～4.4A)
3.7kW(4.9～7.4A) K6CM-CICB200 40～200A
5.5kW(7.3～11A)
K6CM-CICB400 80～400A
7.5kW(10～15A)
11kW(15～22A)
K6CM-CICB600 120～600A
15kW(20～30A)
18.5kW(25～37A)
22kW(29～44A)
30kW(40～60A)
37kW(49～74A)
45kW(60～90A)
55kW(73～110A)
75kW(99～150A)
90kW(110～180A)
110kW(146～221A)
132kW(175～265A)
150kW(198～300A)
200kW(265～401A)
Motor Power & Motor Current
250kW(331～501A)
300kW(397～601A)
CONFIDENTIALB © OMRON Corporation 24
 Monitoring “Degradation Level” (Omron original)
Invertor Conductor
Motor Revolution

or

5 sec 5 sec 5 sec 5 sec 5 sec

No good Good No good Good No good

“Degradation Level” monitoring condition Power

> Monitoring sampling cycle : 5 sec current
> Constant motor speed
> Min. 10 min Motor warm-up (recommend)

* Motor speed should be constant when K6CM monitoring

* If motor speed changing during K6CM monitoring, “Degradation Level”
might be shift bigger. (K6CM might output “Alarm”)
* We recommend motor warm-up operation over 10 min. If motor temp.
is low, baring grease oil might be thick. In this case, “Degradation Level”
Motor
might be shift bigger. (baring trouble)
CONFIDENTIALB © OMRON Corporation rotation 25
 Monitoring “Degradation Level” without Invertor
Conductor

Motor without Invertor

➢ K6CM can determine by “Degradation Level” absolute
value
➢ “Degradation Level” absolute value is not influenced by
motor power (kW) and constant speed revolution (rpm)

Power
current
“Degradation Level” rough indication
> Less [20] : Healthy Motor
> From [20] to [50] : Need motor maintenance
> Equal & More [50] : Recommend motor replace

Motor
CONFIDENTIALB © OMRON Corporation rotation 26
 K6CM Current Analysis “Degradation Level”

Current Analysis image for without Invertor Motor system

That number might be over
“Degradation Level” is changed 100 depend on Motor or Load
when ”Motor” and/or ”Load Degradation failure condition
system” have these failure factors Level

“Degradation Failure factor examples Omron original motor

Level” influence failure analysis level
factor Trouble
Bearing failure Abnormal Bearing 50
Rotor break Motor inside broken 20 : Sign of Motor
system failure
Misalignment Motor coupling failure Need maintenance
(maladjustment) Warning
20
Load Imbalance Load Imbalance like a
50 : Failure of Motor
Fan motor
or Load system
Motor Insulation Motor Insulation aging
failure Elapsed Time

Cavitation Water flow vacuum Default Threshold Healthy Motor Level : 0 to 20

bubble (for water
pump) * In with Invertor system case, “Degradation Level” might be higher number
Overload Excess rotational load even though healthy motor. Hence need to adjust “Threshold” for each motor
system with Invertor.
CONFIDENTIALB © OMRON Corporation 27
 Monitoring “Degradation Level” with Invertor

Motor with Invertor Invertor

➢ K6CM “Degradation Level” absolute value is not correct
for invertor motor system
➢ We recommend to check “Degradation Level” absolute
value for both without invertor and with invertor.
➢ “Degradation Level” will be increased for invertor
system (compared to without invertor system)
➢ “Degradation Level” absolute value is not influenced by
motor power (kW) and constant speed revolution (rpm)
Power
current
“Degradation Level” rough indication
> Initial value is from [50] to [100] : Healthy Motor
but it’s depend on each invertor type.
> [Initial value] + from [20] to [50] : Need motor
maintenance
> [Initial value] + equal & More [50] : Recommend
motor replace
Motor
CONFIDENTIALB © OMRON Corporation rotation 28
 How to define motor trouble or load trouble
Which part may
have problem ? ？
“Degradation Level”
display “Alarm”
？

Loosen Coupling (Joint) Still similar

Remove timing belt “Degradation Level”

Motor load trouble

Motor trouble
Decreasing
“Degradation Level”
CONFIDENTIALB © OMRON Corporation 29
 How to use K6CM-ISM
“Insulation resistance” type

© OMRON Corporation
CONFIDENTIALB
CONFIDENTIAL © OMRON Corporation 30
 Install ZCT

2 types of input voltage

100-240VAC
24VAC/DC Invertor Conductor

ZCT or

You can clamp ZCT for

all 3 wires of motor cable

Up to 7.5kW motor
CONFIDENTIALB © OMRON Corporation 31
 3 phase connection system for K6CM

K6CM Insulation resistance can install these 2 connection system

R

S
3 phase 3 wires S-grounding
T Earth

Delta connection

N
3 phase 4 wires N-grounding
S
T Earth

Star connection
CONFIDENTIALB © OMRON Corporation 32
 Monitoring “Insulation Resistance”

Motor Revolution

10 sec 10 sec 10 sec 10 sec or

No good Good Good Good

“Degradation Level” monitoring condition

> Monitoring sampling cycle : 60 sec (with Invertor)
: 10 sec (without Invertor)
> 3 phase connection system should be “3 phase 3
wires S-grounding” or “3 phase 4 wires N-grounding”
* Motor should run when K6CM monitoring
* Insulation resistance data is not influenced by Invertor
* In Japanese standard case, motor insulation resistance should be more Motor
than 200kΩ (AC200V motor) / 400kΩ (AC400V motor) rotation
CONFIDENTIALB © OMRON Corporation 33
 How to use K6CM-VBM
“Vibration & temp.” type

© OMRON Corporation
CONFIDENTIALB
CONFIDENTIAL © OMRON Corporation 34
 Install Vibration sensor head

Install Vibration sensor head

➢ Drill a hole (M6 x 8mm tap) for sensor that should be
verticalness of Rotary shaft

➢ If customer don’t want to drill a hole on the motor,

sensor head should be glued with attached adapter.
However in this case, K6CM can not detect motor
temperature and high frequency vibration. It means
K6CM can not detect early stage baring failure. M6 ｘ 8mm tap
for Motor body
(flat area)

* Omron does not guarantee motor quality, Baring (inside)

Customer installs Vibration sensor head for motor
CONFIDENTIALB © OMRON Corporation 35
 Monitoring Motor Vibration & Temperature
Not equal due to different motor speed Invertor Conductor
Motor Revolution
Data No.2

or
Data No.1

0.5 sec 0.5 sec 0.5 sec 0.5 sec 0.5 sec
No good Good No good Good No good Power
Preamplifier current
Vibration & Temperature monitoring condition
> Monitoring sampling cycle : 0.5 sec
Temp.
> Constant motor speed Sensor
> Min. 10 min Motor warm-up (recommend) Temperature
Sensor inside

* Motor speed should be constant when K6CM monitoring

* If motor speed changing during K6CM monitoring, vibration data might
not be correct.
* We recommend motor warm-up operation over 10 min. If motor temp.
is low, baring grease oil might be thick. In this case, vibration data might be
Motor
shift bigger. (baring trouble)
CONFIDENTIALB © OMRON Corporation rotation 36