Power Quality Analyzer

Sick & Tired of Burning Up Motors, Capacitors, Drives and Controls???

Transformers Failing and Downtime

Motor Burnout and Downtime

Controls/Displays, Memory Loss and Downtime

VFD Drives and Downtime

80% of These are Caused By Poor Internal Power Quality Which Can Be Identified and Corrected



The MachineSense Power Analyzer

The MachineSense Power Analyzer measures and tracks the following parameters using proprietary MachineSense cloud analytics to locate and diagnose pending failure of stator, motor bearing, and heaters as well as all common line issues such as sag, swell, harmonics, noise, surges. etc.

  • 24/7 Power Analysis for Industrial Applications
  • Easy to Buy, Easy to Install
  • Available in Single and Multiport Variations
Power Quality Analyzer™ - Single Port 30-300 Amps
The Power Analyzer electrical line monitoring system provides detailed power quality and energy consumption information for connected devices. Cloud based...
$1,650.00
Power Quality Analyzer™ - VFD 10-100Amps
The Power Analyzer electrical line monitoring system provides detailed power quality and energy consumption information for connected devices. Cloud based...
$2,325.00
Power Quality Analyzer™ - Single Port 10-100 Amps
The Power Analyzer electrical line monitoring system provides detailed power quality and energy consumption information for connected devices. Cloud based...
$1,550.00
Power Quality Analyzer™ - VFD 30-300Amps
The Power Analyzer electrical line monitoring system provides detailed power quality and energy consumption information for connected devices. Cloud based...
$2,475.00
Power Quality Analyzer™ - 4-Port 30-300 Amps
The Power Analyzer electrical line monitoring system provides detailed power quality and energy consumption information for connected devices. Cloud based...
$3,100.00
Power Quality Analyzer™ - 4-Port 10-100 Amps
The Power Analyzer electrical line monitoring system provides detailed power quality and energy consumption information for connected devices. Cloud based...
$3,100.00
Power Quality Analyzer™ - 2-Port 30-300Amps
The Power Analyzer electrical line monitoring system provides detailed power quality and energy consumption information for connected devices. Cloud based...
$2,475.00
Power Quality Analyzer™ - 2-Port 10-100 Amps
The Power Analyzer electrical line monitoring system provides detailed power quality and energy consumption information for connected devices. Cloud based...
$2,325.00


Power Analyzer measures and tracks

  • Average 3 Phase Voltage
  • Average 3 Phase Current
  • Power Factor
  • Active “Working” Power
  • Reactive “Non-Working” Power
  • Cumulative Active Energy
  • Cumulative Reactive Energy
  • Power Quality Harmonic Distortion for Current & Voltage
  • All Values Needed for Energy Optimization
  • Reports Phase Imbalance

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.

1. MachineSense Component Analyzer 2. MachineSense Power Toroid 3. MachineSense Power Analyzer 4. MachineSense Data Hub 5. Router 6. Cloud-Based Servers 7. MachineSense CrystalBallTM Predictive Software 8. Actionable Maintenance Advice

MachineSenseTM Power Analyzer toroids are placed directly on incoming power lines to automatically monitor power conditions and detect power anomalies. The sensor data transmits through a self-contained data hub directly to your router and onto cloud-based servers running powerful analytic software. Results are then transmitted from the server to either a desktop or user friendly app where you will view power conditions with helpful advice to correct power anomalies.


Features & Benefits


  • Affordable, low investment and easy to install on existing equipment
  • 24/7/365 constant automatic monitoring, no manual measurements
  • Dedicated power supply, no need to change sensor batteries
  • Easy to understand diagnostic advice via text or email messages and handheld or desktop dashboards, no manual data analysis
  • Accurate reporting of potential machine and component failures, to reduce unscheduled machine downtime
  • Real time and historic electrical power consumption data

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.

Electric submersible pumps (ESP) are used in a wide-range of applications from onshore to complex offshore, deep water, or subsea applications. Premature failures during well drilling can lead to high financial loss. It is also well known additional harmonics currents are generated when the ESPs near failure threshold. MachineSense Power Analyzer can detect ESP failures ahead of time. It is also reported, due to overworking of these Pumps during drilling, 10% of the pumps die much before finishing their assigned task in the field. MotorSense can send SMS/email much before ESP pumps develop its fatigue and thus prevents unplanned failure in field which may disrupt production.

Sags are the foremost power quality problem encountered in Industrial applications because they frequently cause the interruption of manufacturing processes, which can result in a significant economic loss due to rejected products . To resolve these problems, industrial consumers often install voltage sag compensators in critical industrial applications. However, these compensating techniques are expensive and at a time ineffective if not designed with proper understanding of the nature of the Sag. The transformer, which is usually mounted in front of the critical load, is likely to be exposed to voltage Sag. As a result, when the compensator reinstates the load voltage, a serious magnitude of transient current begins to flow toward the sensitive load. This inrush current can either damage the equipment or activate the protection devices. In either case, the compensation will eventually fail. MachineSense Power Analyzer tracks both sag and Inrush currents. Industrial operators should be able to monitor both Sag and Inrush current to make sure, neither is affecting their production line.

Data center evolved to become large power consumers. Its supporting infrastructure, such as cooling and power distribution, consumes resources e.g. electric power. Power conditioning and cooling systems constitute largest proportion of Opex for any data center. Therefore, the efficiency of cooling system and power quality are extremely important. There are several designs of cooling and power efficiency but given the infinite permutation of possibility of optimization techniques, Data centers need EnergySense to track several Energy optimization techniques in play at different part of their center and select the best possibility. In addition, if some of the techniques fail to work effectively over the time, EnergySense data can help them sorting out easily as a large of number of EnergySense can be deployed to track the different parts and systems of the Datacenter.

BioTech and pharmaceuticals production is guided by the Federal Drug Administration (FDA) regulations which demand high level of product excellence. High power quality is indispensable in the pursuit of the level demanded by the FDA. Poor power quality and related disturbances can lead to reducing the quality standard and loss of production. Pumps, mixers and motors have to run flawlessly to ensure that the ingredients are mixed in the correct proportions and in the case of capsules, filled properly. Pills cannot be misshapen and high-speed packaging lines must run smoothly. Any glitch in the power quality can result in production losses and even lawsuits. Power Analyzers can be placed at strategic points in the factory to diagnose and record a wide variety of electrical characteristics and automatically report issues to the factory managers or stake holders via SMS and email so corrective actions can be taken.

In recent years, microgrid technologies have captured global interests among governments, industries, and academic institutions due to their potential benefits in improving energy efficiency and reliability, and reducing carbon emissions. A microgrid system should be a single controllable entity that operates in both grid-connected and standalone modes of operation. The total generation capacity, operational capabilities, and network boundary of a microgrid system can vary, depending on types of loads. Microgrid systems have been built on university campuses, military installations, and other industrial sites, for supporting both demonstration and mission-critical activities. One of the primary operational challenges in a building microgrid is associated with power quality management when the microgrid is in standalone operation. Due to the small generation capacity, the physical operating characteristics of building equipment and appliances can considerably affect the microgrid voltage, current, and frequency, and result in harmful harmonic distortions. Therefore, the device operating characteristics must be adequately modeled in both the fast time scales associated with local controls and the longer time scales relevant to energy scheduling. EnergySense cloud provides load/current/harmonics/energy data of the microgrid with easy interface for studying them off-line and real time.

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 industries like textile plastic extrusion for flexible control of power and to reduce the power loss. Unfortunately, solid state drives produce different types of power quality problems. Waveform distortion, particularly harmonics generated by power converters is one of the power quality issues that affect the power system operation. These converter systems generate not only characteristic harmonics but also non- characteristic harmonics like inter harmonics. Power Analyzer measures all kinds of harmonics and current imbalance and if harmonics cross a threshold amount, it sends SMS/Email alerts to the stake holders.

Refrigeration constitutes 20-50% of the operating cost of the food processing Industry. Effective refrigeration or energy efficient cooling is done via 3 major optimizations – thermal shielding, convection of cool air flow and using energy efficient compressors so that least amount of heat is generated. To track effective cooling, one needs to track ambient temperature in all areas of the room and energy efficiency of its cooling compressor. Less efficient compressor will dissipate heat and thus will make system less efficient. Therefore effective tracking of cold storage will need a MachineSense for tracking temperature of cold storage and EnergySense for monitoring compressors for its energy efficiency.

Power factor compensation and harmonic suppression are two important issues in industrial plants because of the installation of a huge number of inductive loads such as electric motors and non-linear power electronic devices that produce harmonic disturbances. Harmonics can shorten the life of industrial equipment and cause transformer overheating, motor failures, fuse blowing, capacitor failures, and malfunction of control systems. In heavy industry plants, an attempt to compensate for low power factor has commonly resulted in installation of medium and low voltage capacitor banks which also help customers avoid penalties from 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. That’s why optimization of configuration and values of capacitor banks is of utmost importance. This can be automatically discovered from harmonics levels and Power Analyzer provides the total harmonics distortion information automatically with a SMS/Email alarm system.

Drying reduces the water content of a product or material. There are various kinds of industrial drying- for example spray drying is particularly used in the dairy industry to increase the shelf-life of a product as well as reduce the cost of transportation. The main challenge in controlling the dryer is to minimize energy (hot air) to bring the residual moisture in the material below the recommended level. Drying accounts for a large proportion of energy bill in the plastic and dairy industry. Now, since several optimization techniques are known for efficiently re-using the hot air for regeneration, it is important to track heat regeneration process for energy efficiency. Dryers can use all the variants of the Power Analyzer analytics packages - EnergySense, MotorSense (tracking the failure of the blower) and HeaterSense (tracking the failure of the heating elements) for predictive maintenance and increasing energy efficiency.

Chemical processing plants need an uninterrupted, high quality, power supply for every part of the process. For example, in hydrocarbon processing, production starts with cracking; the breakdown of large hydrocarbon chains into smaller ones. High pressure steam is superheated, and several general pumps are used to bring water and reactants to the furnace. If a pump fails, the flow of substances in the process will be disturbed. MachineSense Vacuum Pump Analyzer is recommended for such applications. The quencher pump is important to refill the water reservoir of the quencher. The quencher prevents the products from further reaction after the proper temperature has been reached in the furnace or reactor. Long interruptions will lead to unscheduled process downtime, damaging the system. During scheduled downtime, steam is used to de-coke and clean the lines of the furnace to improve reaction efficiency and yield. A five-stage compression process is generally used to dry and compress the products to be separated. During the third stage, the acid gas scrubber uses a pump to spray the gas with a caustic wash, under high pressure, to remove any carbon dioxide and Sulphur. Finally, the dried cracked gas is put through a complex separation process. If a pump or compressor failure occurs, the separation process is affected and the product purity is significantly reduced while lowering the efficiency of the entire process. Thus, in all stages in a refinery plant, pumps play a critical role, failure of which will damage the downstream production. Failure of most of these pumps is caused by higher harmonics and imbalanced powerline fed to those pumps. The Component Analyer can monitor the health of the pumps and compressors 24x7 and any potential risk of the pump or compressor failure will be alarmed. Meanwhile, Power Analyzer can monitor harmonics and line imbalance so you can take corrective actions to minimize damage to these mission-critical pumps.

Specifications

Power AnalyzerTM Single-Port (with isolation) Specifications

POWERSTANDARDRANGEACCURACYRESOLUTION
CurrentIEC600590-50/100/300 amp per phase± 0.3% Full Scale Span0.01
VoltageIEC600380-600 V± 1.2% Full Scale Span0.01
Apparent powern/aup to 310 kVA1% (0.25 Kw MAX)0.01
Total harmonic distortion (V)IEC 61000-4-70-10% upto 5th harmonics (Published)/Upto 27th for THD±2.5%0.01
Total harmonic distortion (I)IEC 61000-4-70-10% upto 5th harmonics (Published)/Upto 27th for THD± 2.5%0.01
Voltage sag/swellIEC 61000-4-30Vsag< 0.8*Vnom, Vswell>1.2 * Vnom
EnergyIEC 62052-11, IEC 62053-21n/a± 2%, - under steady loads.
MECHANICAL
DisplayConnected Mobile / Desktop Android/iOS
Power supply110-270V AC or 24 VDC
Dimension length x width x depth10.0 in X 7.4 in X 2.0 in (255.4 mm X 189.2 mm X 51.7 mm)
Weight1.35 KG without current sensors
SafetyIEC60950-1
ENVIRONMENTAL
Operating temperature14° F to 149°F (- 10° C to 65° C)
Operating humidity<= 90%
Electromagnetic CompatibilityIEC 61326-1
CURRENT I/O
Number of inputs3-phase current input
Current-100A
Current-300A
VOLTAGE I/O
Number of inputs3-phase voltage input
Voltage 0-600V (L-L)
FREQUENCY47.5-63 Hz
DATA ACQUISITION
Resolution24-bit ADC sampling
Sampling frequency1.024 MHz
Input signal frequency47.5-63 Hz
Data storage internal flash memory (not user replaceable)4 GB for local data storage during disconnection
Data rate to cloud1 regular dataset per second. (voltage, current and power factor)
VOLTAGE CABLE
Length2M
Weight2.1 oz (60 g)
Clamp typeCrocodile clamp with banana adapter
Cable specificationPTFE 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
Shielding90% shielding with silver plated copper
ConnectorPG-9 cable gland
CURRENT CABLE
Length2M
Weight (including sensor)5.3 oz (150 g)
Sensor typeSplit core CT
Cable specificationPTFE 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
Shielding90% shielding with silver plated copper
ConnectorPG-9 cable gland

Power Analyzer sensors

Power Analyzer single port

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