EMONITOR Odyssey

AC Motor Rotor Diagnostics Measurements

Entek IRD International
February 19, 1999

Overview
This note describes the setup within EMONITOR Odyssey for the manual
analysis of slip frequency sidebands associated with rotor bar damage. These
instructions cover the measurement setup, diagnostic frequency group setup and
generally accepted guidelines for analysis. In addition, an example template for
rotor bar testing is available. This template includes a high resolution velocity
and current measurement as described in later sections of this note.

Using the Template

The template used for rotor bar measurements is named AC Motor.TPH. This
template includes measurement setups and a diagnostic frequency group. The
template has been setup for use on 4 pole (1800 RPM synchronous speed)
motors. It can readily be adjusted for use on other motors by editing the
frequency setup.
To use the template, follow these steps:
1) Paste the template to the appropriate train in your hierarchy.
2) Enter the correct RPM in the RPM column of the Location Pane.
3) Verify the Motor Speed item in the Frequency Setup view. This item is setup
to identify motor speed from 4 pole motors by searching a 5% band around
1780 RPM.
4) Verify the Synchronous RPM item in the Frequency Setup view. This item is
setup with 1800 RPM as the Synchronous RPM; again this corresponds to a
4 pole motor.
5) Verify the Line Frequency item in the Frequency Setup view. The Line
Frequency entered is 3600 CPM (or 60 Hz), which is used in North and South
America. For other regions, enter the correct local line frequency.
After pasting the template, a new Machine hierarchy item will be added to your
database with two Locations one with a high resolution velocity vibration
measurement and the other with a high resolution current measurement. This
new Machine also includes the diagnostic frequency group that will assist in the
diagnosis of rotor bar problems. These measurements and diagnostic
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frequencies may be added to existing machines by copying and pasting from this
Machine to each additional Machine.
Once the template has been added to your database and adjusted for the
specific machine to be tested, it may be loaded to the data collector and the data
acquired and unloaded to the EMONITOR Odyssey database. At the time the
data is collected, it is also necessary to record the running amps or load
condition of the motor.

Figure 1. Example Rotor Bar Analysis measurement - note 72 dB Delta Y

Analyzing the Current Measurement

The velocity measurement in the template is used strictly to get an accurate
estimate of the machines running speed at the time the data is taken. The
current measurement is used to estimate the rotor bar condition of the AC
induction motor. Rotor bar condition is estimated by following these steps:
1) Plot the spectrum of the current data in a dB scaled format. This may be
done by setting the plot options as shown in Figure 2 below.

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Figure 2. Plot Options used to set Y-Axis for dB scaling with user defined scaling
2) Use a delta cursor and place the first marker on the line frequency of the
current. This will be the largest peak present in the spectrum and will occur at
3600 CPM (60 Hz) (or 3000 CPM (50 Hz) outside of North and South
America). Place the second cursor on the identified Rotor Sidebands items.
There will be two Rotor Sidebands frequencies and the higher amplitude
sideband will give the lesser delta value. Note this value. This gives you the
minimum difference from between the rotor sideband frequencies and the line
frequency peak.
3) For valid testing of an AC induction motor, the motor must be under a
minimum of 25% load. To calculate the percent load the motor is running at,
the running amps should also be recorded during the collection of the motor
data. Assuming you have been using the proper calibration value for the
Current Transformer and Shunt Resistor, this may be read as the peak of the
Current spectrum, which will occur at line frequency. If you are not using a
proper calibration, the running amps may often be read from a gage near the
motor or in a control room. The percent load of the motor may be calculated
from this equation:
(Running Amps-No Load Amps)
Percent Load = ----------------------------------------------(Rated AmpsNo Load Amps)
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For example, when Running Amps = 80; No Load Amps = 20; and Rated
Amps = 100, then
Percent Load = (80-20) / (100-20) = 60/80 = 75%
4) Compare the recorded minimum difference in dB from step 3 to the table
below, to estimate the rotor bar condition.
Minimum dB Difference
> 40
40
30
20

Estimated Rotor Condition

No detectable rotor damage
Some rotor damage present
Rotor damage present and progressing
Severe rotor damage likely present

Using this table and the 72 dB difference from the example data above, there is
no detectable rotor damage on the example motor.

Measurement Setup Details

Two measurements are used for rotor bar testing. The first measurement is a
high resolution velocity vibration spectrum used to identify very accurately the
motor running speed. The second measurement is a high resolution current
spectrum used to pinpoint the rotor sidebands and estimate rotor bar condition.

Figure 3. Location setup from AC Motor template.

In the location pane in Figure 3, two separate locations have been setup, one for
each of these two measurements. The setup of the high resolution velocity
requires a minimum of 3200 lines of resolution in the range from 0 to 6000 CPM
to get an accurate estimate of the running speed of the motor. Figure 4 shows
the measurement pane entries for this velocity measurement and Figure 5 shows
the Collection Specification applied to this velocity measurement.

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Figure 4. High resolution velocity measurement

Figure 5. Collection Specification for high resolution velocity measurement

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The measurement pane in Figure 6 shows the high resolution current

measurement. The setup of the high resolution current requires a minimum of
6400 lines of resolution in the range from 0 to 6000 CPM to get an accurate
measurement of the running amps at line frequency and the rotor sidebands.
Figure 7 shows the Collection Specification applied to this current measurement.

Figure 6. High resolution current measurement

Figure 7. Collection Specification for high resolution current measurement

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Transducer Setup Details

The transducer setup used for the current measurement is based on receiving a
voltage proportional to the measured current. This voltage is converted to a
scaled measurement of the current based on a calibration factor described
below. In order to properly measure this voltage, the transducer is set up
as a standard AC voltage type of measurement. The proper transducer
setups for the dataPAC 1500 and the dataline can be seen in Figures 8 and
9.

Figure 8. Transducer calibration for dataPAC 1500

Figure 9. Transducer calibration for dataline

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Transducer Connection
The current measurements are made from the motor circuit on either the main
phase lead or on a secondary circuit. The measurements are made by using a
CT (Current Transformer) and a shunt resistor. These items are available in the
Entek IRD MOTORMONITOR Hardware Kit. These items are connected as
shown in Figure 10.
NOTE! The CT output must always be connected to a shunt resistor.
Connecting a CT directly to any instrument is dangerous and will damage
the instrument.

Figure 10. Current Measurement Transducer Connection

Typically, the output of the shunt resistor will be connected to a BNC to BNC
cable. To connect this cable to the data collectors the following connectors will
be required:
dataPAC
dataline DSP

#36976
#41532

LEMO to BNC Adapter

Multi-input cable (use AC input)

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Calibration Calculation
The calibration is calculated based on the values of the CT Ratio and the Shunt
Resistor. The CT Ratio is the ratio between the current measured and a
current induced at the CT output. This output current of the CT must be
applied to the Shunt Resistor in order to convert it to an AC voltage, which
may then be measured by the data collector or other instruments. To get
the calibration, divide the Shunt Resistor value in Ohms by the CT ratio.
This will give you a value in volts/Amp. In EMONITOR Odyssey, the
calibration is entered in milliVolts/Amp and the volts/Amp value must be
divided by 10. For a typical 1000:1 CT Ratio and 100 Ohm Shunt Resistor,
the calibration value is .1 Volt/Amp or 100 milliVolt/Amp.

Diagnostic Group Setup Details

A diagnostic group is setup to extract running speed from the velocity
measurement and to use this running speed to identify the 2 x slip frequency
sidebands. These sidebands are readily used to estimate the rotor bar condition
of AC induction motors.

Figure 6 - AC Motor Diagnostic Frequency group setup

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Motor Speed motor speed is setup to be extracted from the high resolution
velocity spectrum. The setup for this can be seen in Figure 7.

Figure 7 Setup for extracting Motor Speed from the high resolution velocity
spectrum
Slip Frequency this is the difference between the synchronous speed and the
actual running speed of the motor. This is setup using the Sum Frequency as
shown in Figure 8.

Figure 8 Slip Frequency setup

2 x Slip Frequency In order to identify the location of the rotor sidebands, it is
necessary to find the 2 x Slip Frequency sidebands around line frequency. The 2
x Slip Frequency calculation is performed as shown in Figure 9 using the
Multiply type.
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Figure 9 2 x Slip Frequency calculated using the Multiply type

Rotor Sidebands these sidebands are the critical frequencies for rotor bar
analysis. These frequencies are setup using the Sideband type as shown in
Figure 10.

Figure 10 Rotor Sidebands setup using the Sideband Frequency type

Conclusion
Using this basic setup, EMONITOR Odyssey can provide a useful additional
function for the manual screening of Rotor Bar condition of AC Induction motors.
Further opportunities are possible within the existing EMONITOR Odyssey
program to perform this analysis in even more detail. These opportunities
include the identification of mechanical influences through additional Diagnostic
Frequency setups, possible alarm setups to automate this, or exporting the data
for automated analysis. These functions will be considered as topics for
additional application notes in this area.

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Collecting current data with the Datapac 1500

For current analysis the db difference between line frequency and the lower side bands are
compared. Therefore, the units that the measurement is collected are irrelevant. The ratio
between line frequency and side bands are maintained regardless of the units used. For this
example the unit of AMPS is used. Note, this is a user defined unit and not the default unit amp.
After unloading, the spectrum will have to be converted to db via the spectrum view in EFW. Also
note a one ohm resistor must be used when collecting current analysis measurements with the
Dpac1500.
1

Calibration (EFW)

-To pull up the calibration screen select setup and then calibration.
-Make sure that the dataPAC 1500 is selected in the collector box.
-Under Transducer name use the ICP Accel (x) transducer. Set the input type to Generic (x).
The selection of transducer name is not necessarily import. The input type should be set to
generic. This will allow you to modify the transducer settings in the dpac.
-The calibration value may vary depending on what type of CT clamp that is being used. It is not
necessary to have the exact calibration value, since you are only comparing the difference
between two peaks. If the dpac displays warning out of range, then the calibration value should
be lowered. Here we used a calibration of 1000. The units are not import. The units of AMPS
were used for consistency.

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Collection Spec

-Fmax should be set for 100Hz or 6000cpm

-Number of lines set to 3200. High resolution is required to separate the peaks.
-transducer set to ICP Accel (X) (for this example).
-Window settings should not matter
-signal detection set to Peak-Peak
-Averaging should not matter

Point set up

-data type spectrum

-units amps (units should not matter)
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-filter none
-collection current

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