Smart MCC White Paper (Final) Siemens

Smart MCCs as a motor maintenance tool
Siemens Energy & Automation, Inc.
www.sea.siemens.com
www.sea.siemens.com/mcc
Smart Motor Control Centers
December 1, 2008
This paper will discuss the application of Smart MCC technology to standard
and predictive maintenance practices used to maximize motor life and help
limit unplanned motor failure. An overview and definition of standard
maintenance practices is followed by a description of information available
from a Smart MCC and how this information can be used.
A white paper issued by Siemens. 2008 Siemens Energy & Automation, Inc. All rights reserved.
White Paper
Smart Motor Control Center
December 1, 2008
Table of Contents
1. Introduction
2. Motor Maintenance Overview
2.1. Time-based Maintenance
2.2. Condition-based Maintenance
3. Siemens Smart MCC Overview
4. Siemens Smart MCC as a Motor Maintenance Tool
4.1. SIMOCODE Pro
4.1.1. SIMOCODE Pro Measured Data for Maintenance
4.1.2. SIMOCODE Pro Statistical Data for Maintenance
10
4.2.3 RW44 Soft-starter
11
4.2.1. RVSS Measurement Data for Maintenance
12
4.2.2. RVSS Statistical Data for Maintenance (Tab 1)
13
14
4.3. MM440 VFD
15
5. Summary
16
6. References
17
End of document
18
This document is not intended as a substitute for any product specific instruction or maintenance manual or
literature. Always consult the manufacturers product specific literature prior to working on or with motors,
MCCs or related equipment.
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1. Introduction
There are significant cost benefits to having a proper motor
maintenance program in place, ranging from 10 percent to
14 percent reduction in energy costs, to avoiding the costs
of unplanned downtime associated with a critical motor
failure (a)(b)(e). Proper application of maintenance practices
to eliminate chronic unplanned failure can lead to a 60%
reduction in maintenance costs, and that can mean millions of
dollars in savings. (n)
Figure 1:
Conditions leading to premature motor failure.
Standard maintenance programs (d)(h)(c) usually gather

statistical data on the motor (number of starts, number of
trips, the number of running hours) and use this data to
determine the lubrication and physical inspection interval.
For the purposes of this paper, we refer to this type of
maintenance as Time-based Maintenance.
However, most motor failures can be anticipated by a few
physical properties of the motor in the operating condition
(temperature, voltage, current, and vibration). The relative
levels of these variables can strongly indicate potential
imminent motor failure. (e)(i) The ability to anticipate
imminent motor failure through real-time monitoring
of physical parameters we refer to as Condition-based
Maintenance or Predictive Maintenance for this paper.
This paper will present an overview of electrical motor
maintenance, and how a Siemens Smart MCC can be used
as either a tool for Time-based Maintenance or Predictive
Maintenance motor maintenance programs. The use of a
Smart MCC in either maintenance program will help mitigate
unplanned motor failures and avoid costly unplanned
downtime.
2. Motor Maintenance Overview
The purpose of a motor maintenance program is to extend
the service life of the motor. The benefits to the customer
December 1, 2008
are reducing overall costs due to unplanned downtime and

premature motor failure.
There are three possible maintenance actions that can be
taken on every motor:
Do nothing
This is sometimes called the run-until-fail maintenance
program. This may be perfectly acceptable for non-
critical low HP motors for items like vent fans.
Time-based maintenance
This means that basic motor maintenance will be
completed based on how long the motor has been
in operation. This is the most common type of motor
maintenance performed on the biggest variety of motors
used in a facility. An example of this type of maintenance
would be proper greasing of the bearings and a physical
inspection.
Condition-based maintenance
This means basic motor maintenance will be completed
based on the how long the motor has been in operation,
plus monitoring vibration or temperature of the motor.
These additional parameters can help predict failure. This
will generally need to be done on process critical
motors, motors that are unique, or have supply
chain issues. An example of this type of maintenance
would be proper greasing of the bearings plus adding
a vibration monitor to insure bearing is still operating
within design limits.
A quick review of the motor characteristics related to motor
maintenance:
Insulation Class
Insulation systems are rated by standard NEMA classifications
according to maximum allowable operating temperatures (d) .
They are as follows:
Insulation Class
Maximum Winding
Temperature
Winding Temperature
Rise Above Ambient
220F
140F to 160F
265F
175F to 195F
310F
220F to 240F
355F
255F to 275F
Table A:
Maximum Winding Temperature for Motor Based on Insulation Class
Generally, a motor should be replaced with one having an

equal or higher insulation class. Replacing a motor with one
of lower temperature rating could result in premature failure
of the motor. Each 10C rise above the maximum winding
temperature (shown in Table A) can reduce the motors service
life by one half.
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NEMA Electrical Design Standards

The following table can be used to help guide which
polyphase design type should be selected.
Classification
Design B
normal
starting
torque and
normal
starting
current
Design C
high starting
torque and
normal
starting
current
Starting
Torque
Percent
Breakdown
Torque
Percent
100 - 200
200 - 250
200 - 250
200 - 250
Starting
Current
Normal
Normal
Slip
< 5%
Fans,
blowers,
centrifugal
pumps and
compressors;
where
starting
torque
requirements
are relatively
low.
< 5%
Conveyors,
stirring
machines,
crushers,
agitators,
reciprocating
pumps;
where
starting
under load is
required.
< 5%
High peak
loads, loads
with flywheels
such as
punch press,
shears,
elevators,
extractors,
winches,
hoists, oil
well
pumping and
wire drawing
machines.
Design D
high starting
torque and
high
starting
current
275
275
Normal
Typical
Applications
Table B:
NEMA Motor Design Standards
Service Factor
December 1, 2008
It is not uncommon for the original equipment manufacturer

(OEM) to load the motor to its maximum load capability
(service factor). For this reason, do not replace a motor with
one of the same nameplate horsepower but with a lower
service factor. Always make certain that the replacement
motor has a maximum HP rating (rated HP x SF) equal to or
higher than that which it replaces. Multiply the horsepower by
the service factor for determining maximum potential loading.
The service life rating of the motor and its use in the loading
of the motor is critical to the life of the motor. Please
consider the amount of voltage unbalance present, ambient
temperature, and winding temperature of motors that have
been designed to run at the maximum service factor rating
of the motor. Consult with the motor manufacturer for the
proper motor to be used as a replacement in these cases.
2.1. Time-based Maintenance
Time-based maintenance is the completion of periodic
maintenance on motors based on general usage parameters,
like the following:
Number of starts
Total hours of running time for the motor
Duty cycle of the motor
Number of overload trips
The premise is that each motor requires lubrication and
physical inspection based on total running time of the motor
per the manufacturer instructions. (k)(l)(m)
Below is listed some general re-lubrication intervals for motors
having grease fittings:
Hours of Service
Per Year
HP Range
Hours of Use Before

Re-lubricaton
5000
1/18 to 7 1/2
10 to 40
50 to 100
5 years
3 years
1 year
Continuous Normal
Applications
to 7 1/2
10 to 40
50 to 100
2 years
1 year
9 months
Seasonal Service Motor is idle for 6

months or more
All
1 year
(beginning of season)
Continuous high
ambient, high vibration
or where shaft end
is hot
1/8 to 40
50 to 150
6 months
3 months
The service factor (SF) is a measure of continuous overload

capacity at which a motor can operate without overload or
damage, provided the other design parameters such as
rated voltage, frequency and ambient temperature are
within the stated specifications for the motor.
Table C:
Motor (re)lubrication intervals
Example: a 3/4 HP motor with a 1.15 SF can operate at

0.86 HP, (0.75 HP x 1.15 = 0.862 HP) without overheating
or otherwise damaging the motor if rated voltage and
frequency are supplied at the motors leads.
In addition, the number of starts, the duty cycle of the motor,

and the number of overload trips can indicate a need for
increased physical inspections of the motor and the process
for changes in operating conditions.
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2.2 Condition-based Maintenance

Condition-based maintenance, as mentioned before, relies
on detecting some physical condition of the motor and
understanding the relationship between the variable being
monitored and motor operation / motor life.
The more operating conditions that can be monitored, the
more data can be gathered to help determine the overall
motor heath, leading to better diagnostics as a part of
condition-based maintenance.
Measure
Current, Voltage,
Voltage Imbalance
Measure
December 1, 2008
can improve the maintenance procedures used by providing

more data collected in a more continuous manner.
1. Each control signal

(start, running, etc.)
has a separate wire
2. No detailed power or
diagnostic data
Traditional MCC
1. Control network for

control and data
(Reduce installation
and startup costs)
2. Detailed power and
diagnostic data
Smart MCC
Figure 3:
Vibration
Comparison of traditional MCCs vs Smart MCCs.
cooling
air flow
stator
fan
rotor
non-drive
end
drive end
It has been estimated that as many as 50% to

75% of all motor failures are bearing related (fXm),
and 95% of all bearing failures are premature (m);
bearing or rotor failure indication is usually
preceded by an increase in motor vibration. (k)(l)(m)
There are three major families of network-enabled

components delivered with the Siemens Smart MCC for
motor control:
Smart Overload Motor Protection (Simocode Pro C / V)
These are network-enabled devices that protect,
monitor, and control the motor starter.
Reduced Voltage Soft-starter (3RW4x)
Network-enabled device that protects and controls the
motor. During the startup of the motor, it will reduce the
voltage to bring the motor gently to its rated speed and
voltage.
Variable frequency drive (MM4xx, 6SE70, Sinamics)
Network enable device that varies the voltage and
frequency of the output to the motor at all times to
control the speed of the motor.
Measure
Stator winding
temperature
Figure 2:
Measurement points for motor condition-based maintenance.
4. Siemens Smart MCC as a Motor Maintenance Tool

A Siemens Smart MCC has components that supply
increased information to support time-based and conditionbased maintenance requirements.
3. Siemens Smart MCC Overview

A Smart MCC is an MCC where the components have
the ability to communicate on a network fieldbus back
to a PLC or DCS. A traditional MCC does not have these
communicating components installed. Through this
network connection, these network components collect
and distribute a larger amount of information than ever.
Since these components are network-enabled and are
designed to deliver larger amounts of information back to a
controlling PLC or DCS, it stands to reason the these devices
SIMOCODE Pro motor management.

This device has the following features:
- Accepts 4-20ma and RTD inputs from external devices
- Accepts additional inputs and outputs for motor control
schemes and protection
- Program contained in device that allows it to operate
with or without a master PLC / DCS controller
- Operating statistics and complete power measurement
data
- Voltage unbalance measurement
- Operator panel
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December 1, 2008
3RW44 Soft- Starter (RVSS)

This device has the following features:
- Operating statistics and complete power measurement
data
- Line and load frequency, plus voltage unbalance
- Ability to accept a motor thermistor input
In general:
MM440 multi-use variable frequency drive

This device is primarily used to match the motor power
or speed output to the process more closely than a full
speed motor. This load / speed matching helps reduce
maintenance and energy use at the same time.
Duty Cycle =
[ Running time (motor) Running time (device) ]
* 100 percent
An important criteria for evaluation of a Smart MCC solution

is to determine where the required information is stored.
Siemens Smart MCCs have the flexibility to store relevant
motor data in the PLC, the motor control device, or both.
This allows retention of data during PLC replacement or
failure.
Duty Cycle = time on x 100%

time on + time off
Therefore for a motor that is connected to a Simocode Pro
motor management unit:
The SIMOCODE Pro provides the following information for

condition-based monitoring:
3 phase current, voltage
Watts and VA
Power quality parameters like:
- Voltage imbalance
- COS-PHI
- Motor model heating
RTD inputs for motor winding temperature
Analog inputs for vibration or other sensors
Digital inputs for additional motor protection
Digital outputs for additional signal or control devices
1. Motor data can be stored in PLC.

2. Motor data can be stored in MCC devices
3. Motor data can be stored in both locations
Choice of locations to save motor operating data

Figure 4:
Location of motor maintenance data.
4.1. SIMOCODE Pro

Standard Smart MCC overloads use the SIMOCODE Pro motor
management as the electronic overload and the motor starter
contactor controller.
The SIMOCODE Pro provides the following information for
time-based maintenance:
Number of starts total
Number of starts left and starts right for a reversing motor
Total hours of operating time for the device
Amount of energy (KW Hours) consumed by the motor
Please note that running time of the motor and the operating
time of the device can be used to determine the duty cycle use
of the motor.
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December 1, 2008
4.1. SIMOCODE Pro Measured Data for Maintenance
Figure 5:
Simocode Pro Maintenance Data
Condition-based maintenance:
These parameters can be used
to review motor winding
heating problems.
Connect optional RTDs to
monitor motor winding
temperature.
Connect optional vibration
sensors to monitor motor
operation.
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December 1, 2008
4.1.2. SIMOCODE Pro Statistical Data for Maintenance
Figure 6:
Simocode Pro Maintenance Data
Time-based maintenance:
Used to determine the motor
duty cycle.
Motor maintenance data used
for service interval and
periodic inspection.
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December 1, 2008
4.2 3RW44 Soft-starter

The Siemens Soft-starter offering used in the Smart MCC is a
product number 3RW44.
The 3RW44 provides the following information for timebased maintenance:
Number of starts left and starts right for a reversing
motor.
Total hours of operating time for the device
Total hours of running time for the motor, plus these
additional motor running categories useful for
calculating the duty cycle based on motor load:
- Operating hours - motor current
18 ... 49.9 percent x Ie(max)
120 ... 1000 percent x Ie(max)
Similar to the SIMOCODE Pro device the duty cycle is
calculated by:
Duty Cycle =
[ Running time (motor) Running time (device) ]
* 100 percent
The 3RW44 provides the following information for
condition-based monitoring:
3 phase current, voltage
Watts
Power quality parameters like:
- Voltage imbalance
- Contact block heating
- Motor model heating
Thermistor inputs for motor winding temperature
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December 1, 2008
4.2. 1. RVSS Measurement Data for Maintenance
Figure 7:
RVSS Measured Real-time Data
Used to determine the voltage
and current unbalance effect
on the motor windings.
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December 1, 2008
Figure 8:
RVSS Statistics Data (Tab 1)
Used to determine total duty cycle for the motor, and to
determine the duty cycle of the motor at 4 different load
levels. Clearly motor life will be impacted most by the duty
cycle of the motor running at greater than 120 percent of
rated load.
Used to determine motor
inspection intervals.
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December 1, 2008
4.2. 3. RVSS Statistical Data for Maintenance (Tab 2)
Figure 9:
RVSS Statistics Data (Tab 2)
Maximum voltage and current determine the life of the
windings based on motor heating models.
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December 1, 2008
4.3 MM440 VFD

The MM440 VFD provides the following information for
time-based maintenance:
The MM440 VFD provides the following information for
conditioned-based maintenance:
3 phase current, voltage, and power
Power Factor, consumed energy
Resistance of rotor and stator windings
Thermistor input for motor winding temperature.
Operational data for motor

performance evaluation
Drive alarms and warnings
Figure 10:
MM440 Motor Operational Data
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December 1, 2008
5. Summary
There are significant cost benefits from employing a
motor maintenance program. These cost benefits are due to
a reduction of unplanned downtime to reduced energy costs.
A time-based maintenance program gathers statistical motor
data (number of starts, running hours, etc) and utilizes this
information to determine motor physical inspection and
lubrication schedules. A condition-based maintenance
program gathers additional real-time physical parameters
(temperature, current, voltage, vibration) to anticipate
imminent motor failures and proactively address motor issues.
Siemens Smart MCCs support either type of maintenance
program, with the following features:
Ability to collect real-time data from the motor
controlling device
Ability to have all relevant motor data read by the
PLC or DCS controller and presented on the operator
HMI. This data can then be printed, avoiding operator
manual data collection processes.
Ability to gather data for time-based and
condition-based motor maintenance.The time-based
data is automatically included on all motor control
devices, but the Simocode Pro can handle optional
RTDs and vibration sensors for condition-based
monitoring programs.
Siemens Smart MCCs are a cost effective addition to any
existing maintenance program, as well as a key enabler to
initiate new motor maintenance programs.
Unique features of Siemens Smart MCC with Profibus-DP
communications include:
Motor data is stored in the motor control devices
Independent operation of the motor control devices
to reduce PLC programming
Extended data and diagnostics are available for
quicker troubleshooting
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December 1, 2008
6. References
a.) Understanding Downtime, www.visionsolutions.com, May 2006
b.) A Simple Way to Estimate the Cost of Downtime, http://roc.cs.berkeley.edu/talks/LISA/ppt, Nov 2002
c.) Motors: Planning for motor failure, E-source Companies, LLC., 2006
d.) Efficiency Opportunities through Motor Maintenance, Pacific Gas and Electric Company, Apr 1997
e.) Test Methods for Determining the Impact of Motor Condition on Motor Efficiency and Reliability
ALL-TEST Pro, LLC., (Undated)
f.) Extend the operating life of your motor, U.S. Department of Energy, Sep 2005
g.) Eliminate Voltage Unbalance, U.S. Department of Energy, Sep 2005
h.) FAQ about Drive Technology, Siemens AG, 2008
i.) Prognostics and Condition-based Maintenance, Pacific Northwest National Laboratory, PNNL-SA-36771, (Undated)
j.) Automated Bearing Wear Detection, DLI Engineering Corporation, 2004
k.) Application Manual for NEMA Motors, http://www.2.sea.siemens.com/NR/rdonlyres/1EE7928A-37F4-44F0-9342-
C35844C09FE3/0/AppManSectionAIIRev1061608.pdf, 2008
l.) Evaluation of antifriction bearing lubrication methods on motor life-cycle cost, Siemens AG, Dec. 1999
m.) Guide to Electric Motor Bearing Lubrication, ExxonMobil, (Undated)
n.) Hidden Treasure: Eliminating Chronic Failures Can Cut Maintenance Costs Up to 60%. Plant Engineering Magazine, Nov
1996
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www.sea.siemens.com
All rights reserved. All trademarks use are owned by
Siemens or their respective owners.
2008 Siemens Energy & Automation, Inc.
December 1, 2008
Siemens Energy & Automation, Inc.

Industry Sector
Drive Technologies and Industry Automation
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Alpharetta, GA 30005
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Smart MCCs as a motor maintenance tool

Siemens Energy & Automation, Inc.

Smart Motor Control Centers

Smart Motor Control Center

2. Motor Maintenance Overview

2.1. Time-based Maintenance

2.2. Condition-based Maintenance

3. Siemens Smart MCC Overview

4. Siemens Smart MCC as a Motor Maintenance Tool

4.1. SIMOCODE Pro

4.1.1. SIMOCODE Pro Measured Data for Maintenance

4.1.2. SIMOCODE Pro Statistical Data for Maintenance

4.2.3 RW44 Soft-starter

4.2.1. RVSS Measurement Data for Maintenance

4.2.2. RVSS Statistical Data for Maintenance (Tab 1)

4.2.3. RVSS Statistical Data for Maintenance (Tab 2)

4.3. MM440 VFD

Smart Motor Control Center

Standard maintenance programs (d)(h)(c) usually gather

are reducing overall costs due to unplanned downtime and

Generally, a motor should be replaced with one having an

Smart Motor Control Center

NEMA Electrical Design Standards

It is not uncommon for the original equipment manufacturer

Hours of Use Before

Seasonal Service Motor is idle for 6

The service factor (SF) is a measure of continuous overload

Example: a 3/4 HP motor with a 1.15 SF can operate at

In addition, the number of starts, the duty cycle of the motor,

Smart Motor Control Center

2.2 Condition-based Maintenance

can improve the maintenance procedures used by providing

1. Each control signal

1. Control network for

Comparison of traditional MCCs vs Smart MCCs.

It has been estimated that as many as 50% to

There are three major families of network-enabled

4. Siemens Smart MCC as a Motor Maintenance Tool

3. Siemens Smart MCC Overview

SIMOCODE Pro motor management.

Smart Motor Control Center

3RW44 Soft- Starter (RVSS)

MM440 multi-use variable frequency drive

An important criteria for evaluation of a Smart MCC solution

Duty Cycle = time on x 100%

The SIMOCODE Pro provides the following information for

1. Motor data can be stored in PLC.

Choice of locations to save motor operating data

4.1. SIMOCODE Pro

Smart Motor Control Center

4.1. SIMOCODE Pro Measured Data for Maintenance

Smart Motor Control Center

4.1.2. SIMOCODE Pro Statistical Data for Maintenance

Smart Motor Control Center

4.2 3RW44 Soft-starter

Smart Motor Control Center

4.2. 1. RVSS Measurement Data for Maintenance

Smart Motor Control Center

4.2.2. RVSS Statistical Data for Maintenance (Tab 1)

Smart Motor Control Center