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Summary of Contents for ABB Ability MACHsense-R
- Page 1 — ABB MOTION SERVICES ABB Ability™ MACHsense-R (MSR1608) Data acquisition unit User manual...
- Page 3 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 Original instructions EFFECTIVE: 2023-12-15...
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Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ..................General safety in installation, start-up and maintenance ........ Electrical safety in installation, start-up and maintenance ......Electrical safety precautions ................General safety in operation ................2 Introduction Contents of this chapter .................. - Page 6 6 Table of contents Configure internet connection ................Activate the SIM card ....................Installing/removing the SIM card ................. Connect the power supply cable ................Using the rubber membrane plate ................ Commission the MACHsense-R ................5 Installing the accelerometers Contents of this chapter ..................Examine the accelerometer mounting location ..........
- Page 7 Table of contents 7 10 Using RS485 interface Contents of this chapter ..................Connecting RS485 inside MACHsense-R ............. 11 Using GPIO interface Contents of this chapter ..................GPIO interface overview ..................GPO connection ......................GPI connection ......................12 Connecting LAN cable Contents of this chapter ..................
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Page 9: Safety Instructions
Safety instructions 9 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. -
Page 10: Electrical Safety In Installation, Start-Up And Maintenance
10 Safety instructions • 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). -
Page 11: General Safety In Operation
Safety instructions 11 ￭ 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. -
Page 13: Introduction
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. -
Page 14: Quick Installation, Commissioning And Operating Flowchart
14 Introduction Quick installation, commissioning and operating flowchart Task See chapter/section Plan and prepare the installation location. Prepare the installation location (page 27) Acquire the accessories needed (SIM card, General requirements (page 24) power cables, sensors, etc.). Supported motor types (page 25) Examine the ambient conditions, input power connection, compatibility of the motor, mo- Technical data (page 69) -
Page 15: Terms And Abbreviations Used In This Manual
Introduction 15 Task See chapter/section Install the accelerometers for vibration Installing the accelerometers (page 35) measurement Install the magnetic field sensor Installing the Magnetic Field Sensor (page 43) Install the DAU Installing the DAU (page 47) Connect the cables Connecting the cables (page 51) Optional: Connect the temperature sensor Connecting temperature sensors (page 59) (PT100 RTD/BTD) -
Page 16: Related Documents
Code (English) ABB Ability™ MACHsense-R (MSR1608) Data acquisition unit quick 4MSL0031 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: support.machsense@abb.com/ ABB local service center/ ABB contact center. Disclaimers ￭... -
Page 17: Cybersecurity Disclaimer
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... -
Page 19: Getting Started
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... -
Page 20: Process Overview Diagram
20 Getting started Process overview diagram... -
Page 21: Package Contents
The delivery package does not include power cable. You can arrange it on your own. See power cable type information on page 30. • MACHsense-R requires an active subscription to access the data collected by the DAU. For more information, contact support.powertrain@abb.com. -
Page 22: Front Panel Information
22 Getting started Front panel information The DAU unit front panel consists of following items: ABB logo QR code Power on LED Lock Safety label Designation label. See description in section Designation label (page 23). -
Page 23: Designation Label
Getting started 23 ￭ Designation label Manufactured by Product name Model number Serial number of format MYYXXXXX, where M: Manufacturing plant YY: 22, 23, ... for 2022, 2023, ... XXXXX: Digits making the serial number unique MAC address of format XX XX XX XX XX XX, where XX: Alpha numeric characters Year of manufacturing Valid markings... -
Page 24: Machsense-R Order Information
Note: The MACHsense-R package does not include SIM card and subscription. You must order it separately, see SIM card and subscription order information (page 24). For further information, contact your local ABB representative or contact the support team (support.powertrain@abb.com). SIM card and subscription order information Article number... -
Page 25: Supported Motor Types
MACHsense-R. The materials are not included in the scope of supply from ABB. You must procure or arrange them on your own. For list of materials included in the package, see Package contents (page 21). -
Page 27: Preparing For Installation
Preparing for installation 27 Preparing for installation Contents of this chapter This chapter describes how to install the MACHsense-R and commissioning it for remote condition monitoring. Prepare the installation location Plan and prepare the installation location. Correct installation assures safe running conditions and maximum accessibility. -
Page 28: Configure Internet Connection
ABB representative. To activate and install the SIM card, do the below steps: Scan the QR code on the ABB SIM card holder using your mobile phone and follow the instructions on the website to complete the SIM card activation. -
Page 29: Installing/Removing The Sim Card
Preparing for installation 29 Installing/removing the SIM card To install or remove the SIM card, do the below steps: Before inserting or removing the SIM card, switch off the power to the DAU and make sure the green plug connectors are not inserted into the high-speed sockets. -
Page 30: Connect The Power Supply Cable
30 Preparing for installation Connect the power supply cable WARNING! Obey the safety instructions required when installing and/or servicing the equipment. 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. -
Page 31: Using The Rubber Membrane Plate
Preparing for installation 31 Using the rubber membrane plate The rubber membrane based cable entry plate can be used to mount cables without connectors into the DAU unit. At the cable entry plate front there are pierceable membranes for various cable diameters. On the back of the plate, there are conical cable sleeves for double sealing of the cables. -
Page 32: Commission The Machsense-R
Dashboard. To commission the MACHsense-R, do the below steps: Download the ABB Ability™ Smart Sensor mobile application through Google play store or the Apple App Store. For China users, use the ABB App store for Android. Google play store Apple App Store ABB App store for Android For Chinese market only. - Page 33 SIM card. Click Next. 7. In the GPRS configuration, if the SIM card is from Swisscom and provided by ABB, select ABB SIM Card option, otherwise select the Manual option to enable the internet APN settings, as shown in above sample screen.
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Page 35: Installing The Accelerometers
For example of mounting locations, see example 1 (page 37) and example 2 (page 38). You can view the correct locations of the sensor in the ABB Ability™ Smart Sensor mobile application, after selecting the profile for attaching the motor asset type... - Page 36 36 Installing the accelerometers See the description of different mounting positions in the below table: Position Description Motor Drive End On the drive end (DE) of the motor, pointing directly towards Horizontal the bearing. Motor Non-Drive End On the Non-Drive End (NDE) of the motor, pointing directly Horizontal towards the bearing.
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Page 37: Example 1: Location Of Accelerometers On Drive End Side Of Motor
Installing the accelerometers 37 ￭ Example 1: Location of accelerometers on drive end side of motor DE Axial On the drive end (DE) of the motor, pointing in the direction of the shaft. DE Vertical On top of the bearing housing, pointing directly towards the bearing. -
Page 38: Example 2: Location Of Accelerometers On Vertically Mounted Motor
38 Installing the accelerometers ￭ Example 2: Location of accelerometers on vertically mounted motor DE Axial On the Drive End of motor, pointing in the direction of shaft. DE Horizontal Mounted perpendicular to the shaft direction near the center of the rotating machine. -
Page 39: Fix The Triaxial Mounting Base
Install mounting pads in motors with fins Some motor types, for example, motors with cooling fins require different type of mounting pads. For more information, contact your local ABB representative. To install the mounting pads in motors with cooling fins, do the below steps: Scrape or grind away any paint or debris between the cooling fins to prepare the motor for mounting. -
Page 40: Mount The Sensors
40 Installing the accelerometers 3. Place the mounting pad between the motor fins in the desired location. Make sure that: • correct motor fin mount type is used. • the probe is fixed between the motor fins, and the bottom of the probe is in contact with the motor casing. -
Page 41: Additional Mounting Information
Additional mounting information • If it is not possible to mount the sensors with glued mounting pads, use alternate mounting techniques. For instructions, contact ABB. • Make sure the point of measurement and sensors are located close to each other and have minimal interfaces to avoid any loss of energy due to high-frequency oscillations in the face of the interface. -
Page 43: Installing The Magnetic Field Sensor
Installing the Magnetic Field Sensor 43 Installing the Magnetic Field Sensor Contents of this chapter This chapter gives instructions for installing the magnetic field sensor (MFS) or the Magnetometer. Examine the MFS mounting location The Magnetic field sensor (MFS) is a three axis sensor that measures axial, radial, and tangential directions. -
Page 44: Mount The Mfs
44 Installing the Magnetic Field Sensor 4. Select the location identified as 3 or 4 on the NDE side (see in below figure) for better signal quality from the sensor and for correct estimation of motor speed. Drive end (DE) Non-drive end (NDE) Mount the MFS The MFS or magnetometer is covered with a plastic case. - Page 45 Installing the Magnetic Field Sensor 45 3. Determine the correct mounting orientations. See the example of correct and incorrect orientations shown in below figures: Correct orientation Incorrect orientation Drive end (DE) Non-drive end (NDE) Make sure that: • Y-axis is parallel to the shaft and the arrow points to the NDE. •...
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Page 47: Installing The Dau
Installing the DAU 47 Installing the DAU Contents of this chapter This chapter gives instructions for installing the Data acquisition unit (DAU). Mounting the DAU The MACHsense-R DAU can be mounted onto the motor or on the neighboring wall or steel structure. You can use a drilling machine to drill the mounting holes and fix the DAU using suitable bolts. -
Page 48: Example Dau Installations
48 Installing the DAU • Avoid mounting directly onto the motor if a mounting plate is not provided on the motor. Obey the instructions from motor manufacturer for mounting directly onto the motor. Example DAU installations The examples below show different ways of mounting the DAU: •... -
Page 49: Mounting On Rails
Installing the DAU 49 ￭ Mounting on rails The DAU can be mounted on an external frame or rail, as shown in below figure. ￭ Mounting directly on the motor The DAU can be mounted directly on the motor, as show in figure below. -
Page 51: Connecting The Cables
Connecting the cables 51 Connecting the cables Contents of this chapter This chapter gives instructions on the wiring of accelerometers and the magnetic field sensors. Wiring and connecting accelerometers After mounting the accelerometers firmly on the motor, connect quick connectors to each sensor. - Page 52 HSCh0 RTN IN 9. The sensor mounting position on the rotating machinery and its connection inside the DAU are predefined in the ABB Ability™ Smart Sensor mobile application during commissioning. For more information, see section Commission the MACHsense-R (page 32).
- Page 53 Connecting the cables 53 10. Make the connections inside the MACHsense-R as defined in the mobile application, otherwise there may be KPI mismatch in the Smart Sensor portal. See the below example of the mounting positions defined in the mobile application as expected in the motor and sensor connections inside the MACHsense-R.
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Page 54: Wiring And Connecting Magnetic Field Sensor
54 Connecting the cables 11. Connect the accelerometer wires to the connector by pushing the wires and pressing the locking mechanism (Red/Orange colored). When connecting the wires between sensor and DAU, make sure the wires are connected with correct polarity. See the wire color codes in the below figure. A ( + ) S i g n a l / P o w e r - I N B ( - ) G N D / C o mmo n - R T N E a r t h s h i e l d... - Page 55 . HSCh7 HSCh6 HSCh5 HSCh4 7. The details of channel cabling inside the MACHsense-R are predefined in the ABB Ability™ Smart Sensor mobile application during commissioning. For more information, see section Commission the MACHsense-R (page 32).
- Page 56 56 Connecting the cables Sensor type Mounting position Channel inside Magnetometer signal MACHsense-R direction Magnetic flux HS Ch 4 X signal Motor body as sugges- ted in section HS Ch 5 Y signal stalling the Magnetic Field HS Ch 6 Z signal Sensor (page 43).
- Page 57 Connecting the cables 57 • Do not allow the sensor to obtain greater acceleration or temperature. • Make sure the sensor location does not hinder other operational and maintenance measures. • Install the mounting hardware or sensors correctly on the application to maximize frequency response, data quality, and long-term adhesion.
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Page 59: Connecting Temperature Sensors
Connecting temperature sensors 59 Connecting temperature sensors Contents of this chapter This chapter describes how to connect the temperature sensors inside the MACHsense-R. Wiring and connecting temperature sensors (PT100 RTD/BTD) inside MACHsense-R MACHsense-R supports the monitoring of motor winding and bearing temperatures if RTD temperature sensors are installed on the stator and bearing. - Page 60 60 Connecting temperature sensors 5. The information of RTD cabling inside the MACHsense-R are defined in the ABB Ability™ Smart Sensor mobile application during commissioning. For more information, see section Commission the MACHsense-R (page 32). Make the connections inside the MACHsense-R similar to the predefined order set in the mobile application, otherwise there may be KPI mismatch in the Smart Sensor portal.
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Page 61: Using Rs485 Interface
Using RS485 interface 61 Using RS485 interface Contents of this chapter This chapter describes the RS485 interface used for Modbus RTU communication in MACHsense-R. Connecting RS485 inside MACHsense-R MACHsense-R uses the RS485 interface for Modbus RTU communication. The RS485 has the following configurations: •... - Page 62 62 Using RS485 interface GPI/PWR OUT/RS485 GPI03 GPI02 GP101 GP100 PWR OUT* RS485 GND A GND GPI GND SV GND 24V NC 5. Connect the serial wires to the connector by inserting the wires into the green terminal and pressing the orange locking mechanism. Make sure proper polarity (as shown in below figure) is used when connecting the wires to the DAU.
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Page 63: Using Gpio Interface
Using GPIO interface 63 Using GPIO interface Contents of this chapter This chapter describes the general purpose inputs and outputs used in the MACHsense-R. GPIO interface overview The MACHsense-R has eight general-purpose inputs/outputs: 4 inputs and 4 outputs. All inputs and outputs are isolated from the logic of using optocouplers. •... -
Page 64: Gpi Connection
64 Using GPIO interface 4. Locate the green connectors with general purpose output terminals marked GPOxx. Check the polycarbonate protective sheet to identify the terminals. PWR OUT/GPO GPO02 GPO00 GPO03 GPO01 PWR OUT* GND GPO 24V GND SV GND 24V 5. - Page 65 Using GPIO interface 65 4. Locate the green connectors with general purpose output terminals marked GPIxx. Check the polycarbonate protective sheet to identify the terminals. GPI/PWR OUT/RS485 GPI03 GPI02 GPI01 GPI00 PWR OUT* RS485 GND A GND GPI GND SV GND 24V NC 5.
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Page 67: Connecting Lan Cable
Connecting LAN cable 67 Connecting LAN cable Contents of this chapter This chapter describes how to install the LAN cable inside the MACHsense-R. Connect LAN cable An Ethernet port is provided inside the MACHsense-R. To connect the LAN cable, do the below steps: Pierce and make a hole in the rubber membrane using a screwdriver to push through the LAN cable without RJ45 plug. - Page 68 68 Connecting LAN cable 4. To configure internet connectivity over the Ethernet interface, contact your IT support team for information of the IP assignment policy. The internet connectivity can be configured using the ABB Ability Smart Sensor mobile application.
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Page 69: Technical Data
Technical data 69 Technical data Contents of this chapter This chapter contains the technical specifications of the MACHsense-R. Software Operating system: Rocko (based on Yocto Linux distribution) Wi-Fi (802.11 a/b/g/n/ac) Name Specification Frequency 2.4 GHz and 5 GHz Tx power max Depending on modulation: •... -
Page 70: Bluetooth (5.0 Br/Edr/Le)
70 Technical data Bluetooth (5.0 BR/EDR/LE) Name Specification Frequency 2.4 GHz Tx power max BR/EDR: 3...10.5 dBm BLE: 1.5...9.0 dBm Rx sensitivity BR/EDR: -20... 80 dBm BLE: -10...-70 dBm Working mode Slave Antenna Dual-band, omni-directional, external, SMA, peak gain 2dBi, shared with Wi-Fi Mobile (LTE 4G, HSPA+ 3G) Name... -
Page 71: Environmental Conditions
Technical data 71 Name Specification Power supply Voltage: 110-240 V AC Power: 20 VA Power indication: LED, front door Environmental conditions Name Specification Temperature -40 °C to +60 °C IP class IP65 Vibration MIL810 Physical conditions Name Specification Housing Steel box Dimensions Width x Height x Depth: 313 x 240 x 157 mm Weight... -
Page 72: Dimensions Of Dau
72 Technical data Dimensions of DAU The figure below shows the dimension drawing for mounting the DAU. Certification Regulatory: CE, FCC, IC ® Loctite AA 326 ® Loctite AA 326 is a yellow to amber, no-mix, medium-viscosity (thixotropic) structural and magnet bonder suitable for magnet bonding and resistant to temperatures of up to +120 °C. -
Page 73: Further Information
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to new.abb.com/service/motion/data-and-advisory-services/condition-monitoring-for-powertrains. - Page 74 4MSL0007A © Copyright 2023 ABB. All rights reserved. Specifications subject to change without notice.