Carbex i-BRUSH User manual

i-BRUSH
Safety and operator’s Manual

i-BRUSH
SAFETY AND OPERATOR’S MANUAL2
i-BRUSH is a measuring system for live
brush data for a variety of applications,
e.g. windmills, hydropower or the process
industry. The system connects directly to
the generator or motor i-brushes and
periodically evaluates measurements of
wear, temperature and other parameters of
interest. Once or more a day, the values
are reported over a cellular or Ethernet
connection to a server making the
information available over the web for the
user.
TABLE OF CONTENTS
Features 3
Technical specification 4
Safety instructions 5
Installation 6
Initial start-up 7
Maintenance 7
Overview front panel 8
I-Brush connectors 9

i-BRUSH
SAFETY AND OPERATOR’S MANUAL3
The main features of the i-BRUSH system are:
■■Measures i-brush wear, temperature and current
■■Measures site temperature and humidity
■■Reports regularly to server, making data available online
■■Triggers alarms for wear and temperature
■■Battery operated, recharging via current coil
■■Connects to server over 2G/3G or Ethernet
■■Optionally connects to external PLC via alarm outputs
■■Complies to IEC 61010-1, EN 301 511, EN 301 908-2
FEATURES

i-BRUSH
SAFETY AND OPERATOR’S MANUAL4
TECHNICAL SPECIFICATION
Max generator voltage
Measurement category
IP Enclosure rating
Size
Operating temperature
Storage temperature
I-BRUSH CONNECTION
3000 V AC (RMS)
CAT IV
IP54
180 x 170 x 85 mm
-20 - +60º C (battery operated)
-40 - +80º C (DC operated)
-40 - +80º C
PRODUCT ID
Supply voltage (optional)
Power dissipation
(when not in standby)
Rechargeable battery
Alarm outputs (isolated)
2G/3G bands/frequencies
5-12V DC, 0.5-2A
0.5W (typ)
10W (max, short moment)
Lion 3.7V/1800 mAh
60V/3A
800, 850, 900, 1900, 2100 MHz
I-BRUSH

i-BRUSH
SAFETY AND OPERATOR’S MANUAL5
SAFETY INSTRUCTIONS
i-BRUSH is directly connected to the
high voltage generator or motor brushes.
Failure to follow the instructions and
safety rules in this manual may result in
serious injury or death.
■■Never do any work on the brushes or
their connection to the i-BRUSH
 systemwithoutrstensuringthe 
 generatorormotoristurnedoandat
rest. Please also follow other grounding
standard procedures.
■■Also make sure the generator or motor
 isoandsecuredwhenmountingor
dismounting the i-BRUSH system.
■■Never open the i-BRUSH box
■■Never tamper or try to repair the
i-BRUSH system or its connections to
the i-brushes. Due to the high voltage,
incorrect or poor repairs can be
hazardous and cause electrical shock or
 re.
■■The i-BRUSH system is designed to be
mounted indoors or in closed
compartments. Any other use will void
the warranty.
■■When carrying and transporting the
i-BRUSH system use the specially
designed box in which it was delivered
to avoid any damage to the system or its
cables and connectors.
WARNING SYMBOL FOR
ELECTRICAL DANGER
WARNING SYMBOL FOR
GENERAL DANGER

i-BRUSH
SAFETY AND OPERATOR’S MANUAL6
The i-BRUSH system should be mounted
close to the generator or motor. It should be
ttedtoametalwallusingitsstrongmagnetic
feet. Ensure the brush cables are routed,
fastened, and able to reach the brush con-
nectors in a satisfactory manner.
Makesurethei-BRUSHsystemisturnedo
before making any connections to it.
Connect the temperature and humidity sensor
to the corresponding connector and “mount”
the sensor on one metal wall using its
magnetic feet.
Mount the i-BRUSH sensor equipped brushes
in the generator or motor and connect each
to one of the six brush cables (8-pin Squba
connector)
Mount the current transformer around one of
the high-power lines (100-800A) and connect
it to the transformer cable of the i-BRUSH
system (2-pin Squba connector).
Alwaysturnoandsecurethegeneratoror
motor before mounting or dismounting
brushes or connecting or disconnecting the
i-BRUSH system! Please also follow other
grounding standard procedures.
INSTALLATION
Optional power feed
If power is available, the i-BRUSH system
can optionally be connected to a DC adapter
(5-12V DC, 0.5-2A). If that is the case, the
current transformer does not need to be used
and connected to the system.
Operation
During normal operation, the i-BRUSH
system will with an interval of a few minutes,
measure all brush parameters for all connected
brushes. It will also measure the temperature
and the humidity in the surrounding area.
These values will be stored and later uploaded
to the i-BRUSH server and made available to
the user. The upload will take place once or
more a day. The upload interval and the
measuringintervalarebothcongurable
parameters in the user web interface.
The system runs on a rechargeable battery
that is charged through the current transfor-
mer input. It will start to charge already at
low load times. Without charging, the system
will run for 2-3 days on the battery.
To save power the system “sleeps” between
the measurement cycles only consuming very
little power.

i-BRUSH
SAFETY AND OPERATOR’S MANUAL7
Every time the system is cold started, ie
turned on with the power button, it will
try to connect to the I-BRUSH server
over the cellular or the Ethernet connec-
tion (ethernet has priority). This will be
indicated on the LED bar by a running
light. When the system successfully has
connected, it will instead show a stable
light indicating the signal strength of the
connection (one bar – very poor signal,
uptovebars–verygoodsignal,or
connected over Ethernet). Note that
connecting over cellular might take
severalminutesthersttime.
If the connection fails, the display will
insteadashwithaxedpattern.
After 30 seconds, the system will go back
to normal operation.
Make sure during the installation of the
system that it manages to connect!
Indicator LED
During normal operation, the indicator
LED shows the wear level of the most
wornbrush.Ifitisashing,thebattery
voltage is low.
When the system “sleeps” between the
measurement cycles, the LED will be
turnedo.
To turn on the indication, press the
wake-up button.
The I-BRUSH system does not require
any special maintenance. If the system
stops working, do not try to repair it or
open it. Doing so will void the warranty.
A broken system should in most cases be
returned to Carbex for repair – always
contactCarbexrstandtheywilladvise
on the action to take.
INITIAL START-UP
MAINTENANCE

i-BRUSH
SAFETY AND OPERATOR’S MANUAL8
OVERVIEW FRONT PANEL
Indicator LED
Connector for
optional Ethernet
connection
Connector for the
temperature and
humidity sensor
Wake-up button
Connector for
optional DC power
Wake
Ethernet
Temp/
Humid
5-12 V DC
larm
3A/60V DC
Alarm connector

i-BRUSH
SAFETY AND OPERATOR’S MANUAL9
I-BRUSH CONNECTORS
Temperature and humidity sensor
Optional DC Power
Alarm outputs
Only use with the i BRUSH
temperature and humidity
sensor
Use a Carbex DC adapter with
5-12V DC output, feeding
from 0.5 to 2A
Mating connector:
Switchcraft EN3C2FX
Mating connector:
Switchcraft EN3C8FX
The four outputs are optoisola-
ted, electronic relay outputs.
They are rated 3A/60V at room
temperature. For safe operation
over the complete temperature
range, do not use more than 1A
Temp/
Humid
5-12 V DC
PIN FUNCTION
1 5 - 12 V
2 GND
PIN FUNCTION
1 Out1 -
2 Out1 +
3 Out2 -
4 Out2 +
5 Out3 -
6 Out3 +
7 Out4 -
8 Out4 +
larm
3A/60V DC

FOR SERVICE AND SUPPORT, PLEASE CONTACT:
CARBEX AB
KVARNBACKSVÄGEN 12
592 41 VADSTENA
SWEDEN
i-BRUSH is designed and developed by
Carbex AB, Vadstena, Sweden.
PHONE: [phone]
EMAIL: [e-mail]
I-BRUSH V1.0 SAFETY AND OPERATOR’S MANUAL Version: 1.0.0