ABB Ability MACHsense-R User manual

—
ABB MOTION SERVICES
ABB Ability™ MACHsense-R (MSR1608) Data
acquisition unit
User manual

ABB Ability™ MACHsense-R
(MSR1608) Data acquisition
unit
User manual
Table of contents
1. Safety instructions
3. Getting started
4. Preparing for installation
4MSL0007 Rev A
EN
Original instructions
EFFECTIVE: 2023-12-15

Table of contents
1 Safety instructions
9Contents of this chapter .........................................................................................
9General safety in installation, start-up and maintenance ................................
10Electrical safety in installation, start-up and maintenance .............................
10Electrical safety precautions ..........................................................................
11General safety in operation .............................................................................
2 Introduction
13Contents of this chapter .........................................................................................
13Purpose of the manual ............................................................................................
13Applicability ...............................................................................................................
13Target audience ........................................................................................................
14Quick installation, commissioning and operating flowchart ..........................
15Terms and abbreviations used in this manual. ..................................................
16Related documents ..................................................................................................
16Disclaimers ................................................................................................................
16General disclaimer ............................................................................................
17Cybersecurity disclaimer .................................................................................
3 Getting started
19Contents of this chapter .........................................................................................
19MACHsense-R overview ...........................................................................................
20Process overview diagram ......................................................................................
21Package contents .....................................................................................................
22Front panel information ..........................................................................................
23Designation label ..............................................................................................
24MACHsense-R order information ..........................................................................
24SIM card and subscription order information ....................................................
24Standard sensors order information ...................................................................
24General requirements ..............................................................................................
25Supported motor types ..........................................................................................
25Required tools ...........................................................................................................
4 Preparing for installation
27Contents of this chapter .........................................................................................
27Prepare the installation location ...........................................................................
27Install the antennas ..................................................................................................
Table of contents 5

28Configure internet connection ..............................................................................
28Activate the SIM card ...............................................................................................
29Installing/removing the SIM card .........................................................................
30Connect the power supply cable ...........................................................................
31Using the rubber membrane plate ........................................................................
32Commission the MACHsense-R .............................................................................
5 Installing the accelerometers
35Contents of this chapter .........................................................................................
35Examine the accelerometer mounting location .................................................
37Example 1: Location of accelerometers on drive end side of motor ......
38Example 2: Location of accelerometers on vertically mounted motor ...
38Fix the mounting pads ............................................................................................
39Fix the triaxial mounting base ...............................................................................
39Install mounting pads in motors with fins ..........................................................
40Mount the sensors ...................................................................................................
41Additional mounting information .........................................................................
6 Installing the Magnetic Field Sensor
43Contents of this chapter .........................................................................................
43Examine the MFS mounting location ...................................................................
44Mount the MFS ..........................................................................................................
7 Installing the DAU
47Contents of this chapter .........................................................................................
47Mounting the DAU ....................................................................................................
48Example DAU installations .....................................................................................
48Mounting on the motor with mounting plate .............................................
49Mounting on rails ..............................................................................................
49Mounting directly on the motor .....................................................................
8 Connecting the cables
51Contents of this chapter .........................................................................................
51Wiring and connecting accelerometers ...............................................................
54Wiring and connecting magnetic field sensor ....................................................
9 Connecting temperature sensors
59Contents of this chapter .........................................................................................
59
Wiring and connecting temperature sensors (PT100 RTD/BTD) inside
MACHsense-R ............................................................................................................
6 Table of contents

10 Using RS485 interface
61Contents of this chapter .........................................................................................
61Connecting RS485 inside MACHsense-R .............................................................
11 Using GPIO interface
63Contents of this chapter .........................................................................................
63GPIO interface overview ..........................................................................................
63GPO connection ........................................................................................................
64GPI connection ..........................................................................................................
12 Connecting LAN cable
67Contents of this chapter .........................................................................................
67Connect LAN cable ...................................................................................................
13 Technical data
69Contents of this chapter .........................................................................................
69Software .....................................................................................................................
69Wi-Fi (802.11 a/b/g/n/ac) ......................................................................................
70Bluetooth (5.0 BR/EDR/LE) ....................................................................................
70Mobile (LTE 4G, HSPA+ 3G) .....................................................................................
70Connectivity ...............................................................................................................
70Power specification .................................................................................................
71Environmental conditions ......................................................................................
71Physical conditions ..................................................................................................
71Installation .................................................................................................................
71Dimension of mounting pads ................................................................................
72Dimensions of DAU ..................................................................................................
72Certification ...............................................................................................................
72Loctite®AA 326 ..........................................................................................................
72Loctite®SF 7649 ........................................................................................................
Further information
Table of contents 7

8

Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install,
start up, operate and do maintenance work on the MACHsense-R data acquisition
unit (DAU).
General safety in installation, start-up and maintenance
These instructions are for all personnel who do work on the DAU.
WARNING! Obey these instructions. If you ignore them, injury or damage to
the equipment can occur.
• Keep the DAU in its package until you install it. After unpacking, protect the
DAU from dust, debris and moisture.
• Handle the DAU carefully, not to drop it down.
• Use the required personal protective equipment: safety shoes with metal toe
cap, safety glasses, protective gloves and long sleeves, etc. Some parts have
sharp edges.
• Do not install or perform maintenance on the DAU on a running motor if the
DAU is mounted directly on the motor. Make sure the motor has cooled
sufficiently for the installation or maintenance of the DAU.
• Make sure that safe platforms are available to access the motor. Do not use
ladders.
1
Safety instructions 9

• Make sure the debris from drilling, cutting and grinding does not enter the
DAU during installation. Electrically conductive debris inside the DAU may
cause damage or malfunction.
• Make sure that there is sufficient cooling. See the Technical data (page 69).
Electrical safety in installation, start-up and maintenance
￭Electrical safety precautions
These electrical safety precautions are for all personnel who do work on the motor
cable or motor. Read this section before you familiarize yourself with the DAU,
initial product setup, and registration process.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work. You must be trained in and be familiar with the specific
maintenance procedures and tests required for rotating electrical machines.
Go through these steps before you begin any installation or maintenance
work.
• Clearly identify the work location and equipment.
• Protect any other energized parts in the work location against contact.
• Take special precautions when close to bare conductors.
• Perform motor repair and maintenance according to the motor’s own
instruction and safety manuals. If a drive unit is included in the motor setup,
follow the additional safety and instruction manuals of the drive.
• Before working on any electrical equipment, obey all the general electrical
safety precautions and local regulations, to prevent injury to personnel. Follow
the instructions issued by the security personnel.
10 Safety instructions
3

￭General safety in operation
These instructions are for all personnel that work around the motor.
WARNING!
Obey these instructions. If you ignore them, injury or damage to the
equipment can occur.
Install emergency stop controls with restart lockouts. After an
emergency stop, a new start command can take effect only after you
reset the restart lockout.
• Installing the DAU requires wiring, so do not try to install when a motor or
connected drive is energized. Do not work on the DAU while the drive, motor
cable, motor, control cables, or control circuits are energized.
• Do not step on the motor.
• Be careful, as the temperature of the motor’s outer casing will be high during
normal operation and especially after shut-down.
• Observe the rotating parts of the motor and take care during installation.
• Do not open the terminal boxes when they are energized.
Safety instructions 11

12

Introduction
Contents of this chapter
This chapter contains information on the purpose of the manual, applicability,
target audience, terms and abbreviations used in this manual, reference documents,
and disclaimer text. It also contains the flowchart of the quick installation,
commissioning and operating steps.
Purpose of the manual
This manual instructs how to install, operate and maintain the ABB Ability™
MACHsense-R (MSR1608) data acquisition unit.
Note: The manual may refer to some general information about various ABB
products. If the information is different than the actual product supplied, the user
can either make an informed engineering judgement as to a course of action, or
contact ABB for more information.
Applicability
This manual applies to ABB Ability™ MACHsense-R data acquisition unit, model
MSR1608.
Target audience
The reader is expected to be a trained personnel with previous experience of similar
tasks and as authorized by the owner of the equipment.
2
Introduction 13

Quick installation, commissioning and operating flowchart
See chapter/sectionTask
Prepare the installation location (page 27)
Plan and prepare the installation location.
Acquire the accessories needed (SIM card,
power cables, sensors, etc.). General requirements (page 24)
Supported motor types (page 25)
Examine the ambient conditions, input power
connection, compatibility of the motor, mo-
tor connection, and other technical data. Technical data (page 69)
Package contents (page 21)
Unpack and examine the units.
Make sure that all necessary accessories and
equipment are present and correct. MACHsense-R order information (page 24)
SIM card and subscription order informa-
tion (page 24)
Only intact units can be started up.
Standard sensors order informa-
tion (page 24)
Required tools (page 25)
Install the antennas (page 27)
Install the antennas
Configure internet connection (page 28)
Configure internet connection and activate
SIM card
Activate the SIM card (page 28)
Activate SIM card or use Ethernet connectiv-
ity Installing/removing the SIM card (page 29)
Connecting LAN cable (page 67)
Connect the power supply cable (page 30)
Connect the power supply
Commission the MACHsense-R (page 32)
Commission the MACHsense-R
14 Introduction

See chapter/sectionTask
Installing the accelerometers (page 35)
Install the accelerometers for vibration
measurement
Installing the Magnetic Field Sensor (page 43)
Install the magnetic field sensor
Installing the DAU (page 47)
Install the DAU
Connecting the cables (page 51)
Connect the cables
Connecting temperature sensors (page 59)
Optional: Connect the temperature sensor
(PT100 RTD/BTD)
Using RS485 interface (page 61)
Optional: Connect the RS485 interface
Using GPIO interface (page 63)
Optional: Connect the GPIO interface
Terms and abbreviations used in this manual.
ExplanationTerm
Measures the vibration or acceleration of motionAccelerometer
Access Point Name is a gateway between a mobile network and an-
other computer network.
APN
Data Acquisition Unit. It is used in a monitoring system to collect
data from different sensors.
DAU
General Packet Radio Service. It is a non-voice high-speed packet
switching system for GSM networks.
GPRS
Global System for Mobile. It is a network connection commonly used
in mobile phones.
GSM
Local area network. It connects devices and applications in close
proximity via Ethernet or Wi-Fi.
LAN
Remote condition-monitoring service for motors and generators.MACHsense-R
Introduction 15

ExplanationTerm
Device that measures the direction, strength, or relative change of
a magnetic field at a particular location.
Magnetometer
Subscriber Identity Module cardSIM card
Sub-Miniature A connector used in cellular signal connections and
radio frequency applications.
SMA
Variable speed drive, also called as frequency converter is used to
regulate the speed and torque of a mechanical equipment.
VSD
Related documents
Code (English)Manuals and guides
4MSL0031ABB Ability™ MACHsense-R (MSR1608) Data acquisition unit quick
installation and start-up guide
For more information about MACHsense-R, go to ABB website:
new.abb.com/products/3BSM045701-1
For product or sales support, contact: [email protected]/ ABB local
service center/ ABB contact center.
Disclaimers
￭General disclaimer
The manufacturer shall have no obligation hereunder with respect to any product
which (I) has been improperly repaired or altered; (II) has been subjected to misuse,
negligence or accident; (III) has been used in a manner contrary to the
Manufacturer"s instructions; or (IV) has failed as a result of ordinary wear and tear.
All material in this manual is subject to change without a further notice. The manual
is intended as non-contractual document.
16 Introduction

￭Cybersecurity disclaimer
This product is designed to be connected to and to communicate through a cellular
network, Ethernet, WiFi and Bluetooth® interfaces. Using the set-up though a
cellular communication network is the most recommended and preferable way to
upload data to the ABB Ability™ Digital Powertrain portal. If the customer is not
using the cellular connection service as provided by ABB and instead prefers to
use their own network communication solution, it is Customer's sole responsibility
to provide and continuously ensure a secure remote connection and establish and
maintain the security of customer’s systems, hardware and software, in particular
those that directly or indirectly connect to the portal. In addition, customer will
without undue delay, completely and accurately implement any software updates
or upgrades provided by the respective vendors and/or by ABB, as applicable.
Introduction 17

18

Getting started
Contents of this chapter
This chapter provides an overview and general requirements for installing the
MACHsense-R DAU .
MACHsense-R overview
The MACHsense-R is a remote condition-monitoring service for motors and
generators. The service consists of the monitoring hardware, referred to as Data
Acquisition Unit (DAU), which is installed on the site. See the process overview
shown in the below Process overview diagram (page 20). The built-in software
within the DAU analyzes the input data collected from different sensors, e.g.,
vibration or temperature. The DAU then transmits the processed data to the ABB
web server, where the engineer can prepare and display the report on a web
front-end for the customer to view.
3
Getting started 19

Process overview diagram
20 Getting started