Intelligent motor control: Real-time data, diagnostics and logic controlled devices

What’s up everyone. Josh Kingsley here, your host for All Things Control by Eaton.

What is an intelligent motor system

In our third installment of What’s in the Trailer, we show you exactly how your motor control application can be made highly intelligent. What I mean is that your application will be able to provide real-time data, diagnostics and the ability to customize the functionality of your control devices with logic.

Let’s explore intelligence made easy.

Three intelligent motor control configurations

We have three intelligent motor control configurations in the trailer for which there are two common control devices:

1. The Power Defense molded case circuit breaker for protection. This small footprint MCCB is globally rated, includes communicating electronic trip units, generates system performance data and can alert you the health of the device. This helps you optimize your facility's performance and reduces the risk of archflash events, thus keeping your employees and customers safe.
   
   
2. Eaton’s PS power supplies for applications like communications networks and PLCs where there is a need for flexibility of operation with universal input voltages. The power supplies also provide system protection and continuous operation during brief current surges of up to 150% of nominal current for components with high in-rush demands.

Intelligent motor control with XT IEC Contactors and Power Xpert c445

Let’s look at our first configuration. The control devices included here are Eaton’s XT IEC contactors, combined with an intelligent motor management relay called the Power Xpert C445. XT IEC contactors stand out for their reduced power consumption, which makes them more energy efficient. C445 provides among the highest level of monitoring accuracy and protection for your motor application. 

Protections can range from the incoming power source feeding the motor to the individual pump or load conditions. This powerful device comes standard with built-in user-defined logic and multiple ground fault detection capabilities. You also have the ability to create custom functions with your own logic. Now that’s intelligence that you might not have expected. This dynamic duo is ideal for continuous process applications like oil refineries and chemical plants.

Intelligent motor control with S811 soft starter and easyE4 PLC

Our next configuration features the S811+ soft starter combined with the easyE4 nano programmable logic controller or PLC. The S811+ features a soft stopping pump control option that provides a smooth transition for stopping a motor to eliminate the “water hammer” effect that can be found in water pumping applications. 

The soft starter also provides advanced protective and diagnostic features using sophisticated algorithms that model motor heating. This results in fewer nuisance trips and reduced downtime. The easyE4 nano PLC has 12 inputs and outputs and can be expanded to a network of up to 188 I/O points, providing the ideal solution for lighting, energy management, industrial control, irrigation, pump control and HVAC.

Intelligent motor control with PowerXL DM1 VFD and XT IEC safety contactor

Our final configuration consists of Eaton’s PowerXL DM1 micro variable frequency drive, XT IEC safety relay and an XT IEC safety contactor. The DM1 offers a robust collection of features in one device including Bluetooth technology, which allows you to manage and control system faults remotely in real-time. 

The XT IEC safety relays and contactors provide additional levels of protection for high-risk machine applications like machining centers. Although the DM1 comes standard with SIL 2 safety rating, combining it with the relays and contactors allows you to achieve SIL 3 safety rating, which improves your ability to keep your personnel and equipment protected.

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