Zero-downtime non-intrusive electrical monitoring from the MCC: diagnosing motor broken rotor bars, stator turn faults, and mechanical eccentricity via high-resolution current demodulation.
Monitors internal electrical health without touching the rotating asset. Identifies fractured rotor bars, high-resistance joints, and inter-turn insulation decay while the machine operates under normal production loads.
Current passing through the motor feeder generates a concentric alternating magnetic field in the high-permeability grain-oriented silicon steel or permalloy core. A precision secondary winding produces a secondary current proportional to the primary current. When rotor bars crack or stator insulation degrades, the motor air-gap flux modulates the stator current, creating distinctive sidebands around the fundamental line frequency (50/60 Hz).
Feeder Magnetic Flux → Permalloy Split-Core CT → Precision Burden Resistor → Differential Instrumentation Preamp → Simultaneous Multi-Channel 24-bit ADC at 25.6 kS/s → Optruss MCSA High-Resolution FFT Spectral Demodulator.
Confirm motor is de-energized or follow NFPA 70E live-panel safety protocols
Verify arrow stamped on CT housing points in the direction of power flow (Grid to Motor)
Inspect core mating faces for dust or foreign particles to ensure zero air-gap closure
Tighten core latch securely until an audible click confirms positive mechanical lock
Clip the split-core transformer around Phase A, B, and C insulated feeder cables between the contactor/overload relay and motor output terminals. Connect secondary wiring using twisted shielded 18 AWG cable to the Optruss MCC acquisition card. No de-terminating of power cables is required.
Pole-pass sideband amplitude calculation: fb = fL(1 ± 2s)
Distinct sidebands around the 50/60 Hz line frequency; sideband amplitude within 45 dB of fundamental indicates broken bar
Negative sequence current vector & high-order harmonic ratios
Sharp rise in negative-sequence current asymmetry exceeding 1.5% alongside elevated slot harmonics
Rotational speed sidebands around principal slot harmonics
Sideband pairs spaced at running frequency (fr) around fundamental rotor slot harmonics
Low-frequency current demodulation spectrum
Periodic current envelope modulation reflecting mechanical load pulsations from reciprocating compressors or pumps
Optruss MCC Engine captures high-resolution 120-second current waveforms at steady operating load. It calculates the slip frequency ($s$), identifies pole-pass frequency sidebands, and computes the Broken Rotor Bar Index. If the sideband delta shrinks to within 45 dB of the fundamental carrier, AssetCore initiates an ISO 14224 Stage 2 electrical degradation alert.
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Benefit from sub-millisecond edge FFT processing, early P-F curve anomaly detection, and automated CMMS work order generation.
