POWER QUALITY ANALYZER
Sick & Tired of Burning Up Motors, Capacitors, Drives and Controls?
Overview
Overview
Every manufacturer has electrical issues. These issues can, and will, affect productivity, machine
performance and electrical costs. As in the past, most plant engineers, plant managers and maintenance
managers tend to focus on mechanical issues often because they simply don’t understand electrical
issues, or how to diagnose them. When machines break down the typical response is to have expensive
instrumentation and highly paid consultants come to the plant to figure out what’s going on. As a
result, most plant managers just avoid diagnosing the real problem and instead just swap out mechanical
or electrical components or motors that have failed, or reset PLC units that have dumped their programs.
In other words, they implement the easy and expensive quick fix, but not the right solution.
Studies show that plant management teams don’t always understand electrical issues because most of them
are not versed on internal electrical distribution issues including areas such as power factor,
harmonics, swells, and sags . This can easily lead to inefficient factory productivity and performance
because, quite honestly, there is a knowledge gap on how to effectively measure, understand and act upon
electrical factors in the plant.
MachineSense, and our proprietary Power Analyzer technology, is designed to capture, interpret and
diagnose relevant data obtained from electrical components and internal power distribution. MachineSense
products are specifically designed to help diagnose everyday electrical issues and present them
factually in a way that can be easily understood by plant management regardless of any electrical
engineering experience on electrical components and related issues.
How It Works?
How It Works?
1. MachineSense Power Toroid
2. MachineSense Power Analyzer
3. Vibration Analyzer
4. MachineSense Data Hub
5. Router
6. Cloud-Based Servers
7. MachineSense CrystalBallTM Predictive
Software
8. Actionable Maintenance Advice
Watch this video to see how MachineSense Power Analyzers can improve power quality and reduce machine downtime:
Features & Benefits
Features & Benefits
Applications
The growing line of MachineSense Power Analyzers has been designed for many industrial
electrical applications—to help identify key electrical issues and possible pricing
concerns as well as to help identify looming failure issues in motors, drives and
heaters.
In the past, looking for power quality issues has typically only been a last resort
because most plant management personnel are not fully educated in electrical issues.
However, research has shown that many equipment issues are founded on electrical power
quality problems. Instead of making power quality a review of last resort, it should be
used as a first survey by most process manufacturers.
Poor power quality shows up in many ways and can absolutely affect the performance of
machine controls which are essentially computers nowadays. In addition, it can affect
the performance and life of components such as heaters and motors. A recent survey
indicated that US businesses lost a staggering $188 billion a year just because of
internal power quality issues that are often not diagnosed or misdiagnosed and happen
again and again and again.
Most industrial factories in the US were set up long before the age of computerization,
computer controls and sophisticated variable frequency drives. Electrical building
contractors designed facilities without thinking that computers would be on every desk,
let alone every machine controller. Furthermore, they designed only for motors running
at their design speed and lighting that emitted low harmonic output. All of this led
electrical contractors and electrical engineers in the past to have little reason to be
concerned about harmonics, transients and other power factor issues. As a result,
internal plant power is often a major undiagnosed problem that constrains productivity,
increases utility charges and often causes electrical or computer failures. For example,
most plant personnel assume that motor failures are the fault of the motor or the
machinery supplier and just replace the motor. However, the vast majority of motor
failures are due to power quality problems.
Most industrial factories in the US were set up long before the age of computerization,
computer controls and sophisticated variable frequency drives. Electrical building
contractors designed facilities without thinking that computers would be on every desk,
let alone every machine controller. Furthermore, they designed only for motors running
at their design speed and lighting that emitted low harmonic output. All of this led
electrical contractors and electrical engineers in the past to have little reason to be
concerned about harmonics, transients and other power factor issues. As a result,
internal plant power is often a major undiagnosed problem that constrains productivity,
increases utility charges and often causes electrical or computer failures. For example,
most plant personnel assume that motor failures are the fault of the motor or the
machinery supplier and just replace the motor. However, the vast majority of motor
failures are due to power quality problems.
MachineSense Power Analyzers are the first series of economically priced instrumentation
designed by and for manufacturers to help them understand electrical issues and act on
them so they avoid the continuation of undiagnosed electrical issues occurring on an
ongoing basis. Some of the diagnostic tools that can be used include the following:
Power Factor
Harmonics
Sag
Swells
Power Usage
One of the biggest advantages of MachineSense Power Analyzers is that it is easily to install and easy to understand the readouts. In addition, the power analyzer can record power usage and other conditions over an extended period of time as many fluctuating power conditions are random events that can’t be adequately shown over a day or two period.
Solid State Drives There is a very high usage of power converters in the modern power system because of their high efficiency. Solid state drives are extensively used in the modern industries (Textile, Extrusion in Plastic) for flexible control of power and to reduce the power loss. Unfortunately, solid state drives produce different types of power quality (PQ) problem. Waveform distortion, particularly harmonics generated by power converter is one of the PQ issues that affect the power system operation. These converter systems generate not only characteristic harmonics but also non characteristics harmonics like inter harmonics. Electrosense measures all kinds of harmonics and current imbalance and if harmonics crosses a threshold amount, it sends SMS/Email alerts to the stake holders.
Power Factor Suppression & Harmonic Compensation Using Capacitor Banks
Power factor compensation and harmonic suppression are two important issues in industrial plants because of installation of huge number of inductive loads such as electric motors and non-linear power electronic devices that produce harmonic disturbances. Harmonics in industrial plants can shorten the equipment’s life and cause transformer overheating, motor failures, fuse blowing, capacitor failures, and malfunction of control systems. In heavy duty plants, the low power factor has commonly been compensated by installing medium and low voltage capacitor banks which also help customers avoiding penalties to the utility, reducing extra losses in transformers, overhead lines and cables. However banks of capacitors and Industrial inductors when placed together can create a lot of undesired frequencies due to resonance which have been learned to be harmful. That’s why optimization of configuration and values of capacitor banks is of utmost importance so that resulting configuration of inductors and capacitance don’t result in undesired frequencies. This can be automatically discovered from harmonics levels and Electrosense provides the total harmonics distortion information automatically with a SMS/Email alarm system.
Oil & Gas
MachineSense can identify power factors for individual machines or for an internal distribution line. Since utilities often charge a penalty in their bills to customers with poor power factor, this information can help identify power factor problems and ultimately reduce your energy bill—paying for MachineSense quickly and easily. Low power factor means not only are you paying too much for electricity, but also significantly compromising your electrical efficiency.
Being able to measure power factor is a key initial step to understanding your plant’s electrical system.
Current & Sag-Powering Transformer-Coupled Loads
Energy Optimization in Data Centers
Bio-Tech & Pharmaceutical
Energy Scheduling in Microgrids in Commercial Buildings
Solid State Drives & High Harmonics in Industrial Lines
Refrigeration in Food Storage & Processing
Power Factor Suppression & Harmonic Compensation Using Capacitor Banks
Energy Optimization of Drying in Plastic, Diary & Food Processing
Oil Refineries & Chemical Processing
POWER | STANDARD | RANGE | ACCURACY | RESOLUTION |
---|---|---|---|---|
Current | IEC60059 | 0-50/100/300 amp per phase | ± 0.3% Full Scale Span | 0.01 |
Voltage | IEC60038 | 0-600 V | ± 1.2% Full Scale Span | 0.01 |
Apparent power | n/a | up to 310 kVA | 1% (0.25 Kw MAX) | 0.01 |
Total harmonic distortion (V) | IEC 61000-4-7 | 0-10% upto 11th harmonics (Published)/Upto 27th for THD | ±2.5% | 0.01 |
Total harmonic distortion (I) | IEC 61000-4-7 | 0-10% upto 11th harmonics (Published)/Upto 27th for THD | ± 2.5% | 0.01 |
Voltage sag/swell | IEC 61000-4-30 | Vsag< 0.8*Vnom, Vswell>1.2 * Vnom | ||
Energy | IEC 62052-11, IEC 62053-21 | n/a | ± 2% |
MECHANICAL | |
---|---|
Display | Connected Mobile / Desktop Android/iOS |
Power supply | 110-270V AC or 24 VDC |
Dimension length x width x depth | 10.0 in X 7.4 in X 2.0 in (255.4 mm X 189.2 mm X 51.7 mm) |
Weight | 1.35 KG without current sensors |
Safety | IEC60950-1 |
ENVIRONMENTAL | |
Operating temperature | 14° F to 149°F (- 10° C to 65° C) |
Operating humidity | <= 90% |
Electromagnetic Compatibility | IEC 61326-1 |
CURRENT I/O | |
Number of inputs | 3-phase current input |
Current-100A | |
Current-300A | |
VOLTAGE I/O | |
Number of inputs | 3-phase voltage input |
Voltage 0-600V (L-L) | |
FREQUENCY | 47.5-63 Hz |
DATA ACQUISITION | |
Resolution | 24-bit ADC sampling |
Sampling frequency | 1.024 MHz |
Input signal frequency | 47.5-63 Hz |
Data storage internal flash memory (not user replaceable) | 4 GB for local data storage during disconnection |
Data rate to cloud | 1 regular dataset per second. (voltage, current and power factor) |
VOLTAGE CABLE | |
---|---|
Length | 2M |
Weight | 2.1 oz (60 g) |
Clamp type | Crocodile clamp with banana adapter |
Cable specification | PTFE Insulated 0.40 Sq.mm - Silver Plated Copper - 600 V - 6 Core - Shielded Cable Description: Awg.22/19/34 - SPC - E - 6 Core - TEF / SPC / TEF Cable OD : 4.50 mm + / - 0.50 mm |
Shielding | 90% shielding with silver plated copper |
Connector | PG-9 cable gland |
CURRENT CABLE | |
Length | 2M |
Weight (including sensor) | 5.3 oz (150 g) |
Sensor type | Split core CT |
Cable specification | PTFE Insulated 0.40 Sq.mm - Silver Plated Copper - 600 V - 6 Core - Shielded Cable Description: Awg.22/19/34 - SPC - E - 6 Core - TEF / SPC / TEF Cable OD : 4.50 mm + / - 0.50 mm |
Shielding | 90% shielding with silver plated copper |
Connector | PG-9 cable gland |
Power Analyzer sensors
Power Analyzer single port