Motor condition monitoring for pumps, fans and rotating equipment
Motor condition monitoring combines two different jobs on the same asset: fast electrical protection and slow trending of mechanical condition. The first reacts to short circuits, overloads and phase faults. The second records vibration, bearing condition and load behaviour over weeks, so a developing fault is visible before it trips the plant. LOGGON TECH supplies both sides of this chain, and this page lists the models used for rotating equipment monitoring on low-voltage motors, pumps and driven machinery.
Where the category is used
In most plants the motor is the cheapest part of the drive train and the pump, fan or gearbox behind it is the expensive one. Motor condition monitoring therefore serves two purposes: protecting the motor itself, and using the motor as a sensor for the machine it drives. Pumps, fans, compressors and conveyors all produce a characteristic vibration pattern. A rise in vibration at the bearing locations, a change in starting behaviour, or a slowly drifting load current is what equipment health monitoring is built to catch.
The typical application profile is a low-voltage plant motor, 380 VAC and below, with a contactor or soft starter as the switching device. Space in the MCC bucket is limited, the plant network is industrial Ethernet, and the maintenance team is small. That shape of installation drives the model selection below. Protection devices sit in the bucket with the contactor; condition monitoring nodes can be distributed at the machine or concentrated in one cabinet. In a proposed architecture, both can feed a common trend record (integration confirmed per project), which is where online condition monitoring earns its place: data is collected without a planned outage or a walk-round route.
Models in this range
LOGGON-3S intelligent motor protection controller
The LOGGON-3S is the protection device in the bucket. Its protection set covers start timeout, short circuit, locked rotor, tE time, overload, unbalance, underload, thermal overload, process interlock and grounding. During and after a protection action the controller records alarms, trips, maximum and minimum values, and cumulative motor running time. The running-time record is the basis for maintenance intervals and for comparing an aged motor with its commissioning data.
| Protection functions | Start timeout, short circuit, locked rotor, tE time, overload, unbalance, underload, thermal overload, process interlock, grounding |
|---|---|
| Event records | Alarms, trips, maximum and minimum values during protection actions, cumulative motor running time |
LOGGON-2M intelligent motor protection controller
The LOGGON-2M extends the protection set with under-voltage and over-voltage, leakage, power and power-factor protections. It also controls starting directly: direct-on-line, reverse, reduced-voltage and star-delta starting, either locally or remotely. Anti-sag restart resumes the motor after a stop caused by a supply dip, so a short voltage sag does not leave a pump or fan off-line. Power and power-factor supervision link the electrical side of motor health monitoring to the mechanical side.
| Additional protection functions | Under-voltage, over-voltage, leakage, power, power factor |
|---|---|
| Starting control | Direct, reverse, reduced-voltage and star-delta, local or remote |
| Restart function | Anti-sag restart after a dip-caused stop |
M60 traditional motor protection controller
The M60 is the conventional controller for low-voltage motors rated below 800 A at 380 VAC. It is used where a standard protection controller is specified; the LOGGON-500 2M documents an extended monitoring function list.
| Rated application | Low-voltage motors below 800 A at 380 VAC |
|---|
LOGGON-V1 multi-channel condition monitoring instrument
The V1 is the monitoring side of the system. It is installed at the first signs of a fault and then monitors continuously, in parallel with the protection devices. Up to 64 sensor nodes connect to one instrument. Communication is via Ethernet, with optional 4G. The unit runs on battery or mains supply and is rated for -40 to +60 °C, so it can be mounted in an outdoor or unheated enclosure as well as in a cabinet. Remote expert diagnosis is available on the collected data.
| Sensor nodes per instrument | 64 max. |
|---|---|
| Typical communication rate | 200 kbps |
| Network interfaces | Ethernet; optional 4G |
| Operating temperature | -40 to +60 °C |
| Power supply | Battery or mains |
| Service | Remote expert diagnosis |
401D / 401B wireless vibration sensors
The 401D and 401B are wireless vibration sensors with a ±16 g triaxial range and a 10–5000 Hz frequency band. That band covers the range where bearing defects and imbalance on pumps and fans normally appear. Because the sensors are wireless, bearing condition monitoring can be added to machines that have no spare cable route.
| Measurement range | ±16 g, triaxial |
|---|---|
| Frequency band | 10–5000 Hz |
How to select
- Check the motor rating and switching device. The M60 covers LV motors below 800 A at 380 VAC by its documented rating. Choose LOGGON-2M where the motor starts in star-delta or reduced-voltage and where the supply is prone to dips, because anti-sag restart and the under/over-voltage protections apply. Choose LOGGON-3S where the main concern is mechanical or process faults on a motor that starts direct-on-line.
- Check the starting method and the required control location. Direct and reverse starting, reduced-voltage and star-delta control are functions of the 2M.
- Check how many machines need trending. The V1 handles up to 64 sensor nodes, so one instrument can serve a group of pumps or a fan bank.
- Check the bearing locations on each machine. One triaxial sensor per bearing housing captures all three axes, so count bearings rather than axes.
Integration and communication
The protection controller sits in the MCC bucket and responds to electrical faults locally at the bucket. The V1 collects trend data; its documentation lists a typical transmission rate of 200 kbps and one Ethernet port with an optional 4G module as separate fields, and the 4G option serves machines the plant network does not reach. Mounting temperature is -40 to +60 °C, which allows the instrument to follow the machine into the field rather than staying in the control room. Plan the sensor count against the 64-node limit and leave margin for machines added later. Confirm the V1 supply arrangement (rechargeable battery or mains) and the monitoring availability required during trips in the project design.
FAQ
What is the difference between protection and condition monitoring?
Protection reacts to electrical faults such as short circuit, locked rotor or overload; protection settings and operating times are confirmed for the selected model. Motor condition monitoring follows mechanical health over weeks, using vibration and load trends. The two functions complement each other and are usually installed on the same motor.
Can a LOGGON-V1 handle a whole pump room?
One V1 supports up to 64 sensor nodes. If each bearing housing carries one 401D or 401B triaxial sensor, count the bearing locations in the room against that limit before ordering.
Which controller handles star-delta starting?
The LOGGON-2M controls direct, reverse, reduced-voltage and star-delta starting, locally or remotely. The LOGGON-3S covers the core protection set; the extended starting control (direct, reverse, reduced-voltage and star-delta, locally or remotely) is documented for the LOGGON-2M.
Will the motor restart after a voltage dip?
The LOGGON-2M includes anti-sag restart, which resumes the motor after a stop caused by a supply dip.
For a selection check, send the motor rating, starting method, bearing layout and the network available at the machine. LOGGON TECH will confirm the controller and the V1 sensor count against those figures.