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

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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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© 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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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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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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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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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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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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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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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.

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4.2 Europe compliance
Caution: RoHS and REACH Confirmatory Statement
The documentation for thisdevice complies with technical documentation for theassessment of electrical
and electronic products with respect to the restriction of hazardous substances as per EN 50581:2012.
·Failure to observe and follow the instructions provided with the equipment and accompanying
manuals could cause permanent damage to the equipment and could lead to property damage,
personal injury and/or death.
·Before attempting to use the equipment, you should review this instruction manual in its entirety,
including all caution and danger indicators.
·If the equipment is used in a manner not specified by the manufacturer or functions abnormally,
proceed with caution. Otherwise, the protection provided by the equipment may be impaired and
could result in improper operation and injury.
·Installation and service personnel must be familiar with general device test practices, electrical
awareness and must take proper safety precautions when installing and/or servicing the
equipment.
·Before performing installation, inspections, tests or maintenance on this device or associated
circuits, all live circuits and sources of electric power to said device and circuits must be isolated
or disconnected.
·Failure to shut off equipment prior to removing power connections could expose you to dangerous
voltages that could cause injury or death.
·All electrical equipment should be properly grounded and must have a reliable and
uncompromised grounding path. Equipment grounds should be properly bonded and connected
to the facility’s primary ground system for primary power.
·At all times, equipment must be properly grounded during device operation, maintenance and
service.
·All electrical connections and grounds must comply with all applicable laws, regulations and
electrical codes.
·Personal Protection Equipment shall be used to avoid injury. Safety shoes, safety hard hat,
protective goggles, ear protectors, gloves are recommended.
·When working with chemicals, you should get the safety data sheet from the supplier’s web page.
For more information regarding MACHsense-R, please visit www.abb.com
For answers not found in the support centre website or for product assistance, please contact
[e-mail] or the ABB Local Service Centre or ABB Contact Centre.

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5 Get started
5.1 Quick summary of the MACHsense-R
·MACHsense-R kit consists of a package of Data Acquisition Unit (DAU) vibration sensors,
mounting pads, sensor cables, and installation manual.
·A web portal is used for showing data. For web address, please contact ABB.
·Wired or wireless sensors are connected on motors and MACHsense-R DAU is programmed to
pick up signalsrelating to the motor’s health and operatingparameters. The collected data is then
transferred via GPRS to MACHsense-R secure ABB-designated server.
·The data will be processed by algorithms, developed by ABB, and turned into meaningful
information for the user to view and manage in the portal.
·The DAU is an IP56 certified device; housed in painted stainless-steel casing.
MACHsense-R is meant for condition monitoring and not for protection purposes.
5.2 The requirements for the use of MACHsense-R
·MACHsense-R portal access
·Internet connectivity for the DAU
Expected data upload volume from MACHsense-R to the ABB secure cloud is about 1 GB per
motor per month
·Motors
Both ABB and non-ABB motors can be monitored
Note the motor specifications supported by MACHsense-R:
·Standard 3 phase induction motor >355 frame size
·Cast iron or rib cooled frame
·S1 operation

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5.3 Preparations for installation
5.3.1 General
Adequate planning and preparation results in correct installation, assures safe running conditions and
maximum accessibility.
During installation, general as well as local safety instructions must be followed.
5.3.2 Power supply
·MACHsense-R requires external power supply 110-240 V AC
·Recommended fuse is 10 A
·Recommended cable area is 1.5 mm2
·Installation should be made by certified electrician according to local regulations and applicable
standards.
5.3.3 Tools and materials
Suitable materials for set-up as well as other auxiliary tools for installation are normally not included in
the ABB delivery. Auxiliary tools for installation are to be supplied by the customer.

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6 Installing DAU
6.1 Installation kit
The MACHsense-R kit contains the following:
Item description
DAU
Accelerometers (four)
Mounting pad (four)
Cable (four, 10 m each)
Installation guidelines
The recommended way of installing vibration sensors is to glue the mounting pads into their correct
position on the motor.
·Recommended glue: Loctite AA326
·Recommended Activator: Loctite SF7649
·Recommended cleaner Loctite 7061
Note: Mounting glue is not included in the MACHsense-R package.
Safety Data sheet are available at the Loctite website http://www.henkel-adhesives.com.
Always have the Safety Data sheet available and follow the instructions carefully.

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6.2 Mounting DAU
Monitoring device can be mounted on the motor or on neighbouring wall or steel structure depending on
the feasibility of the condition. Drilling machine can be used for drilling mounting holes and fixing DAU
using suitable bolts.
MACHsense-R pictures

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DAU Mounting Holes and Space Requirements
Small clamp to be welded to the base with 20 mm projection from left and right sides,
horizontal hole pitch is 260 mm.
Vertical hole pitch is 200 mm when the clamps are aligned 42.5 mm from the top and
bottom sides of the baseplate.
L bracket to be welded to the base with 12.5 mm projection from the edge.
Following precautions have to be taken into account while mounting DAU:
·Select mounting location which is a non-hazardous areas and free of shock forces, excessive
dust, close proximity to electrical appliances, etc.
·Selected mounting location and subsequent mounting of DAU should allow trouble free cabling.
·The DAU should be mounted where it is easy accessible for service technician to connect laptop
into the LAN connector inside the DAU.
·Sufficient reserve should be provided for connectors.
·Ensure correct fastening of mounting bolts to prevent any sudden unfastening due to external
forces.
·Ensure proper laying of cables. Use cable ties and fasteners to secure the cables.
·Mounting directly on motor should be avoided. For further instructions please consult Motor
manufacturer for mounting instructions.
6.3 Communications
The DAU communicates with the specific server over a General Packet Radio Services (GPRS)
connection. A SIM card is required for the GPRS or 3G connection.
In addition to GPRS it will be enabled to use Wireless Local Area Network (WLAN) or Ethernet.
6.4 Example of Installation
·The DAU can be mounted on assembly plate of the motor. Drilling and tapping of holes will be
required for this. Motor manufacturer should be consulted.

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·The DAU can also be mounted on the same side as auxiliary terminal box to reduce the cable
length for RTD, BTD.
-For non-Ex- applications: Cable length up to 500 ft. (150 m) can accurately
transmit data from sensors (datasheet)
-For Ex- applications:Cable length upto 1600 ft.(480 m) can accurately transmit
data from sensors (datasheet) – FUTURE RELEASE
Examples of Mounting DAU on a Machine

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7 Installation of Accelerometers (Vibration Measurement)
7.1 Accelerometers Location
Accelerometer mounting locations are as follows:
·Channel 0 is DS horizontal direction
·Channel 1 is NDS horizontal direction
·Channel 2 is DE Axial direction
·Channel 3 is DS vertical direction
When mounting accelerometers, it is important to locate the best positions on the motor. The
accelerometer is single axis and measures only in one direction.
Accelerometer diagram and technical specs
Channel 0: Motor Drive End horizontal direction. Find a position on the side of the motor. This position
should be pointing directly in towards the bearing.
Channel 1: Motor Non-Drive End horizontal direction. Find a position on the side of the motor. This
position should be pointing directly in towards the bearing.
Channel 2: Motor Drive End Axial direction: Find a position on the side of the motor. This position should
be pointing in the direction of the shaft.
Channel 3: Motor Drive end vertical direction. Find a position on top of the motor. This position should be
pointing directly in towards the bearing. This sensor should be mounted 90 degrees to the DE Horizontal
direction sensor.

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7.2 Mounting of pads
Procedure for gluing the pads:
1. All paint must be removed from the surface. Make sure all paint is grinded and the pad is glued
directly on the metal on the motor.
2. Clean the surface with recommended cleaner Loctite 7061.
3. After the cleaner has dried, apply glue Loctite AA326 on the mounting pad. Make sure you put
glue on the side where the threaded mounting hole is not positioned.
4. Spray some activator Loctite SF7649 on the glue and on the surface on the motor. Immediately
attach the pad in correct position and keep steady for 15 minutes.
Mounting pad diagram and technical specs
LOCTITE AA 326 is a yellow to amber, no-mix, medium viscosity (thixotropic) structural
and magnet bonder which is suited to magnet bonding and resistant to temperature up
to +120°C; LOCTITE 326 is activated with LOCTITE SF 7649.
LOCTITE SF 7649 (known as LOCTITE 7649)
Surface Preparation – activator that is solvent-based with low temperature curing. LOCTITE SF 7649 is
designed to promote the curing speed of LOCTITE anaerobic adhesives and sealants without any
significant loss of joint strength.
Adhesive
Mounting Adaptor
MH130-6A

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Ensure to understand and follow the instructions and information of adhesive and
cleaning products for safe and correct use.
Make sure to use personal safety equipment and make sure the area is well
ventilated.
7.3 Mounting of sensors
Mount the accelerometers in the mounting pads by screwing the sensor into the pad.
Mounting torque: 2.7 to 6.8 Nm
7.4 Additional information on mounting
There are alternative mounting techniques for mounting sensors, if it is not possible to use these glued
mounting pads. Please consult ABB for alternative recommendations for mounting.
The point of measurement is chosen so that point of measurement and sensor are mechanically as close
as possible to each other. The sensor should bemounted as close as possible to the bearingand pointing
towards the shaft centreline.
·High-frequency oscillation loses some of its energy in the face of the interface. Therefore, the
measuring point has to be chosen in such a way that the point of measurement and the sensor
have minimal interfaces.
·Vibration of rotating equipment is transferred to the bearings through the body. So, the
measurement points should be selected as close as possible.
·The sensor mounting point has to be chosen correctly so that the space available allows for the
sensor installation and replacement.
7.5 Wiring and connection of sensors
Quick connector
1. Connect the quick connector to each sensor and put the cable to the DAU.
2. After mounting the sensor, the cable should be anchored to reduce stress at the cable ends and
to prevent false signals due to cable vibration and slapping. Cables that are allowed to have
excessive motion will eventually result in cable metal and insulation fatigue. The fatigue causes
wire strand breakage, insulation failure, and results in noisy or broken connections.
3. Use cable ties or clamps to secure cables without being left hanging loose. When securing the
cable, leave enough slack cable to allow free movement of the accelerometer on the vibrating
machinery. These techniquesfor cable anchoring areextremely important for machinery with high
displacement amplitudes.