ABB MACHsense-R User manual

Document kind Document identity Revision
Instruction 1MZB100400 A
Owner organization Document type Date of revision (yyyy-mm-dd) Status Page(s)
Motors and Generators Instruction manual for MACHsense-R -
MSR1600 2017-05-19 Draft 1(31)
Division/Department Prepared by Approved by Security level
RMMG / PG Service Jan Wallden, Lillemor Rapp,
Laxminarayan Daund Henrik Ryegard Confidential
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties
without express authority is strictly forbidden.
© Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION
Instruction manual
for
ABB MACHsense-R
MSR1600
Reviewed by:
Jan Wallden, Lillemor Rapp
Approved by:
Henrik Ryegard
Document no.: 1MZB100400
Revision A

Document type Document identity Revision Page(s)
Instruction manual for MACHsense-R - MSR1600 1MZB100400 A2(31)
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties
without express authority is strictly forbidden.
© Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION
Contents
1 Introduction.......................................4
1.1 General information........................4
1.2 Standards.........................................4
1.3 Important note.................................4
1.4 Limitation of liability........................5
2 Recycling and scrapping ................6
3 Safety Instructions...........................8
3.1 Safety precautions..........................8
3.2 General safetyduring MACHsense-
R installation................................................8
3.3 Electrical safety during
MACHsense-R installation ........................8
4 Important instructions.....................9
4.1 USA & Canada compliance ..........9
4.2 Europe compliance.......................11
5 Get started .......................................12
5.1 Quick summary of the
MACHsense-R..........................................12
5.2 The requirements for the use of
MACHsense-R..........................................12
5.3 Preparations for installation ........13
6 Installing DAU .................................14
6.1 Installation kit.................................14
6.2 Mounting DAU...............................15
6.3 Communications...........................16
6.4 Example of Installation.................16
7 Installation of Accelerometers
(Vibration Measurement).......................18
7.1 Accelerometers Location.............18
7.2 Mounting of pads..........................19
7.3 Mounting of sensors.....................20
7.4 Additional information on mounting
20
7.5 Wiring and connection of sensors
20
8 Installation in Motors with Fins....23
9 Installation of Magnetic Field
Sensor (MFS).......................................... 24
9.1 MFS Location.................................24
9.2 Mounting of MFS Sensor.............24
9.3 Wiring and Connection of Sensor
25
10 Configuration.................................. 26
10.1 Preparation.....................................26
10.2 Commissioning..............................30
11 Terms for using ABB MACHsense-
R – MSR1600 product/service ............. 31

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Instruction manual for MACHsense-R - MSR1600 1MZB100400 A3(31)
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without express authority is strictly forbidden.
© Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION
© 2017 ABB Inc. All rights reserved.
The contents of this manual are the property of ABB Inc. This documentation is furnished on license and
may not be reproduced in whole or in part without the permission of ABB Inc. The content of this manual
is for informational use only and is subject to change without notice.

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Instruction manual for MACHsense-R - MSR1600 1MZB100400 A4(31)
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express authority is strictly forbidden.
© Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION
1 Introduction
1.1 General information
This instruction manual contains information on the installation, operation, and maintenance of the ABB
MACHsense-R MSR1600. Also referred to MACHsense-R in this manual. MACHsense-R package
consists of Data Acquisition Unit (DAU), vibration sensors, mounting pads for sensors, 10 meters cables
for connecting sensors, and Installation guidelines for MACHsense-R - MSR1600.
Careful study of the contents of this manual and other related documentation before any actions are
taken is necessary to ensure proper functionality and a long lifetime.
Actions shown in this manual are only to be performed by trained personnel with previous experience in
similar tasks, and authorized by the owner of the equipment.
This document and parts thereof must not bereproduced or copied without theexpress written permission
of ABB, and the contents thereof must not be imparted to a third party nor be used for any unauthorized
purpose. ABB constantly strives to improve the quality of the information provided in this instruction
manual, and will welcome any improvement suggestions. For support, contact the closest ABB Local
Service Centre LSC or ABB-Certified Service Centre.
These instructions must be followed to ensure safe and proper installation, operation and maintenance
of the DAU. It should be brought to the attention of anyone who installs, operates or maintains this
equipment. Ignoring the instruction invalidates the warranty.
1.2 Standards
The MACHsense-R is designed and certified to fulfil the following standards and directives:
·CE
·LVD
·RED
·RoHS
·WEEE
The MACHsense-R unit is also IP 65 certified.
1.3 Important note
The information in this document may sometimes be of a general nature and applicable to various
products produced by ABB. Where a conflict exists between the contents herein and the actual product
supplied, the user must either make an informed engineering judgement as to a course of action or, if
any doubt exists, contact ABB.
Safety is dependent on the awareness, concern and prudence of all those who operate and service
machines. While it is important that all safety procedures be observed, care near machinery is essential
- always be on your guard.

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Instruction manual for MACHsense-R - MSR1600 1MZB100400 A5(31)
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express authority is strictly forbidden.
© Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION
To avoid accidents, safety measures and devices required at the installation site must be in accordance
with the instructions and regulations stipulated for safety at work. This applies to general safety
regulations of the country in question, specific agreements made for each work site and safety
instructions included in this manual and separate safety instructions delivered with the machine.
1.4 Limitation of liability
In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any
nature or kind arising fromthe use of this document,nor shall ABB be liable for incidental or consequential
damages arising from use of any software or hardware described in this document.
The warranty issued covers manufacturing and material defects. The warranty does not cover any
damage caused to the DAU, personnel or third party by improper storage, incorrect installation or
operating of the machine. The warranty conditions are in more detail defined according to Orgalime
S2000 terms and conditions.
The warranty issued is not valid, if the operation conditions of the DAU are changed or any changes in
the construction of theMACHsense-R, or repair workto the MACHsense-R have been made without prior
written approval from the ABB factory.
Local ABB sales offices may hold different warranty details, which are specified in the
sales terms, conditions or warranty terms.

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Instruction manual for MACHsense-R - MSR1600 1MZB100400 A6(31)
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express authority is strictly forbidden.
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2 Recycling and scrapping
This product cannot be disposed of as unsorted municipal waste in the European
Union. For proper recycling return this product to your supplier or a designated
collection point as per your municipal rules.
2.1.1 General
The manufacturing process of the machine is carried out in accordance with the Environmental
Management System ISO 14001.
This instruction concerns the disposal and recycling of ABB MACHsense-R. The equipment is designed
in a way that itis easy to separate the different components and types of material fromeach other, making
it easier to recycle.
The methods are described in a very general way. All instructions are to be performed
by personnel which is trained and skilled for the procedure.
2.1.2 Dismantling the equipment
Risk of personal injury when dismantling the machine. Use proper PPE when
dismantling.
·Only skilled and trained personnel should carry out the dismantling.
·Dismantling the machine is done by simply separating all the components of the equipment.
·When the equipment has been dismantled into its different components, the different components
has to be separated and grouped together dependent upon the different types of material.
2.1.3 Separation of different types of material
Stainless steel – SS-304
·Enclosure
·Cable tray
·Screws, Standoff, Nuts
Aluminum
·Heat Sink
·Power module Tray
·Power Supply Cover

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Instruction manual for MACHsense-R - MSR1600 1MZB100400 A7(31)
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express authority is strictly forbidden.
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Polyurethane soft foam (FrenchFoam A-7-146-VP4)
·Gasket
oCable gland plate
oTop cover plate
Copper: Different types of wires/cables used in DAU
Polycarbonate sheet: Transparent sheet to shield
·PCB:
oMain Board
oA/C input board
oPoE board
Carbon Steel
Not used
Special high quality steel
Not used
Mixed metallic material
Not used
Electronic waste
The below items should be disposed and recycled as “electronic waste” as per WEEE directive:
·Cables
·PCB
·Power supply unit
·WiFi module
·GPRS module
·Ethernet module
·Any part of the DAU
Hazardous waste
Not used.
-----------
If there is some questions of environmental matters not considered in this instruction, please get in
contact with the Environmental Coordinator of the ABB Machine Division.

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Instruction manual for MACHsense-R - MSR1600 1MZB100400 A8(31)
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express authority is strictly forbidden.
© Copyright 2017 ABB PROPRIETARY AND SECRET INFORMATION
3 Safety Instructions
3.1 Safety precautions
These instructions are for all personnel who work on the motor. Personnel performing maintenance on
electrical equipment and installations must be certified. The personnel must be trained in, and familiar
with, the specific maintenance procedures and tests required for rotating electrical machines.
Motor repair and maintenance should be performed following the motors own instruction and safety
manuals. If a variable frequency drive (VFD)1unit is included in the motor setup, please follow also the
VSD unit’s additional safety and instruction manuals.
Before working on any electrical equipment, general electrical safety precautions must be taken into
account, and local regulations must be respected in order topreventpersonnel injury. Thismust be made
according to instructions issued by the security personnel.
Personnel performing maintenance on electrical equipment and installations must be certified. The
personnel must be trained in, and familiar with, the specific maintenance procedures and tests required
for rotating electrical machines. Please read this section before you familiarize yourself with the
MACHsense-R, initial product setup, and registration process.
3.2 General safety during MACHsense-R installation
·Handle the MACHsense-R carefully and must not be dropped.
·Use safety shoes with metal toe cap during installation to avoid foot injury.
·Don’t install or perform maintenance on the DAU on a running motor.
·Make sure that the motor has cooled enough for the installation or maintenance of MACHsense-
R.
·Make sure to use safe platforms to access the motor. Do not use ladders.
·When drilling be aware of hot cutting chips. Always wear safety goggles and adequate safety
equipment.
3.3 Electrical safety during MACHsense-R installation
Installing the MACHsense-R will require wiring, so do not try to install when motor or connected drive is
energized. Do not work on the MACHsense-R while VSD unit, motor cable, motor, control cables or
control circuits are energized.
General points to be observed when working around the motor:
·Do not step on the motor.
·Be careful since the temperature of the outer casing of the motor will be high during normal
operation and especially after shut-down.
·Observe rotating parts of the motor and take care during installation.
·Do not open terminal boxes while energized.
Emergency stop controls must be equipped with restart lockouts. After emergency
stop, a new start command can take effect only after the restart lockout has been
intentionally reset.
1Also known as variable speed drive (VSD) unit

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Instruction manual for MACHsense-R - MSR1600 1MZB100400 A9(31)
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express authority is strictly forbidden.
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4 Important instructions
As per Radio Equipment Directive (2014/53/EU minimum separation distance of 20
cm between the user and radiating antenna on MACHsense-R shall be maintained
when it is switched on – either in installed or in troubleshooting status.
Hazardous voltages and rotating parts can cause shock, burns or other injuries,
including death.
4.1 USA & Canada compliance
Caution: FCC and IC RF Radiation Exposure Statement
FCC statement
This device complies with part 15 of the FCC Rules. Operation is subject to the following two
conditions:
(1) This device may not cause harmful interference, and
(2) This device must accept any interference received, including interference that may cause
undesired operation.
FCC Caution statements
1. Any changes or modifications not expressly approved by the party Responsible for compliance
could void the user's authority to operate this Equipment.
2. This equipment should be installed and operated with minimum distance 20 cm between the
radiator & your body.
NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance
with the instruction manual, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.

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Instruction manual for MACHsense-R - MSR1600 1MZB100400 A10(31)
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express authority is strictly forbidden.
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Attention: FCC et IC Déclaration d'exposition aux radiations RF
Déclarations ISDE
Cet appareil est conforme aux normes RSS exemptes de licence d'Industrie Canada. Son
fonctionnement est soumis aux deux conditions suivantes:
(1) Cet appareil ne doit pas provoquer d'interférences nuisibles, et
(2) Cet appareil doit accepter toute interférence reçue, y compris les interférences pouvant entraîner un
fonctionnement indésirable.
Déclarations de mise en garde d'ISDE
Tout changementou modification non expressément approuvé par la partie responsablede la conformité
pourrait annuler le droit de l'utilisateur à utiliser cet équipement.
2. Cet équipement doit être installé et utilisé à une distanceminimale de 20 cm entre le radiateur et votre
corps.
REMARQUE: Cet équipement a été testé et jugé conforme aux limites d'un appareil numérique de classe
A, conformément à la section 8.4 de RSS Gen. Ces limites sont conçues pour fournir une protection
raisonnable contre les interférences nuisibles lorsque l'équipement est utilisé dans un environnement
commercial. Cet équipement génère, utilise et peut émettre de l'énergie de radiofréquence et, s'il n'est
pas installé et utilisé conformément au manuel d'instructions, peut provoquer des interférences nuisibles
aux communications radio. Le fonctionnement de cet équipement dans une zone résidentielle est
susceptible de provoquer des interférences nuisibles, auquel cas l'utilisateur devra corriger les
interférences à ses frais
Note :
The deviceintegratesCellular GPRSModem HE910-D from Telithaving FCCIDRI7HE910 and Wireless
Transmitter module WF111-E from Silicon Labs having FCC ID QOQWF111 for radio communication.
The modules are integrated to this product as per the module integration rule.