Predictive Motor Breakdown Monitoring During Operation
CPS-MM-LC Three-Phase Motor Insulation Monitor. Continuous resistance measurement without equipment shutdown. Up to 30kW motor support with φ25mm ZCT sensor included. Built-in IoT functions - no PC or cloud required.
Challenges Engineers Face in Motor Maintenance
Traditional motor inspection methods require equipment shutdown, leading to production losses and high maintenance costs. Real-time monitoring eliminates these challenges.
Unexpected Production Line Stops
Production lines stop unexpectedly due to motor breakdowns and electricity leakage accidents
Production Plan Disruption
Production plans are disturbed, leading to unnecessary costs
Disassembly Inspection Costs
Disassembly costs occur each time inspections are performed
Secondary Malfunction Risk
There is a concern of secondary malfunctions due to incorrect wiring
Limited Status Visibility
The status during operation can only be judged from data measured while equipment was stopped
Insufficient Trend Data
This data cannot be used to determine trends as it is obtained over a short period of time
These aren't edge cases—they're the norm for traditional motor maintenance. But what if there was a different approach? One designed specifically for continuous monitoring without equipment shutdown?
Predictive Maintenance Timeline
See how insulation deterioration progresses from healthy baseline through warning stages to critical maintenance window
Risk Events & Failure Prevention
Visualize 3 critical failure modes (Grounding Fault, Phase Short Circuit, Layer Short Circuit) and how CPS-MM-LC prevents them
CPS-MM-LC Motor Insulation Monitor Solution
Continuous monitoring without equipment shutdown. Predictive maintenance through real-time resistance measurement. Built-in IoT functions eliminate need for PC or cloud infrastructure.
Monitor During Operation
- Measures insulation resistance from operating motors (I0r components)
- No equipment shutdown required for inspections
- Continuous monitoring with high precision
Prevent Unexpected Failures
- Clear deterioration trends enable accurate judgment
- Repairs and replacements performed before breakdowns occur
- Reduces unplanned downtime and production losses
Boost Equipment Operating Ratios
- Operating ratios are boosted, unnecessary costs are reduced
- Inspection costs are reduced (no disassembly required)
- No need to stop power supply during work inspections
No PC or Cloud Required
- Built-in data collection, web monitoring, cloud linking
- Can be operated without a PC
- Web-based programming with Visual Task Control (VTC)
Key Specifications
30kW
Motor Power Support
Three-phase low-voltage
1ch
Measurement Channels
Single channel monitoring
φ25mm
ZCT Sensor Diameter
Zero Current Transformer
Complete System Architecture
From motor to cloud: CPS-MM-LC module integrates with M2M controller for autonomous monitoring without PC or specialized software
Edge Device Layer
CPS-MM-LC module measures insulation resistance from operating motors (I0r components) with φ25mm ZCT sensor, no shutdown required
Control Layer
M2M Controller CPU provides web HMI server, local database storage, VTC programming, and optional cloud linking
Monitoring Layer
Real-time dashboard via web browser, custom HMI screens, alert notifications, and optional cloud platform integration
CPS-MM-LC Motor Insulation Monitor
Three-Phase Motor Insulation Deterioration Monitoring Module with continuous resistance measurement capability
CPS-MM-LC Module Product Image
Model Number
CPS-MM-LC
Product Specifications
Measurement Channels
1ch (single channel monitoring)
ZCT Inside Diameter
φ25mm (Zero Current Transformer included)
Measured Voltage Range
Line to Line: 10 VAC to 600 VAC
Motor Support
Up to 30kW three-phase motors
Connection Types
Three-phase delta and Y connections
System Integration
Requires M2M controller CPU module
Continuous
Monitoring
Predictive
Maintenance
Autonomous
Operation
Measurement Modes & Configuration
CPS-MM-LC supports two measurement modes for different motor drive configurations: Power Supply Mode for direct NFB connections and Inverter Mode for VFD systems
Power Supply Mode
Measurement Point E (Power Output Section)
Direct power supply measurement for standard motor installations. Measures overall equipment leakage current from power output section after circuit breaker.
Leakage Current Range:
0 to less than 1A (overall equipment measurement)
Resolution: 0.001mA
Applications:
- Standard three-phase motors
- Water pumps and compressors
- HVAC fans and building equipment
Inverter Mode
Inverter / AC Servo Amplifier Output
Inverter and AC servo amplifier output measurement for variable frequency drive systems. Monitors leakage current specific to inverter-controlled motors.
Leakage Current Range:
0 to less than 100mA (inverter/servo output)
Resolution: 0.001mA
Applications:
- Variable frequency drive (VFD) systems
- CNC machines and servo motors
- Precision automated equipment
Common Specifications (Both Modes)
Voltage Range
10-600 VAC
Line to line voltage
Insulation Resistance
<1,000 MΩ
Measurement range
Accuracy Specification
<10 MΩ
High-precision range
Measurement Mode Selection Guide
Interactive decision tree to help you select the appropriate measurement mode (Power Supply or Inverter) based on your motor drive configuration and application requirements
Key Features & Capabilities
Comprehensive motor insulation monitoring with built-in IoT functions and predictive maintenance capabilities
Continuous Monitoring During Operation
Monitoring can be performed at all times during operation. Measures insulation resistance from operating motors with I0r components precision.
Real-time measurement without interruption
Predictive Breakdown Prevention
By predicting breakdowns, repairs and replacements can be performed before breakdowns occur. Clear deterioration trends enable accurate judgment.
Enables proactive maintenance scheduling
No Equipment Shutdown Required
There is no need to stop the power supply or perform disassembly during work inspections. Inspections no longer require equipment to be stopped.
Zero downtime for inspections
Supports Up to 30kW Motors
Supports low-pressure, three-phase motors up to 30kW. Compatible with three-phase delta connections and three-phase Y connections.
Up to 30kW motor power support
Built-in IoT Functions
Autonomous device that does not require a PC or Cloud connection. Built-in functions include data collection, web monitoring, and cloud linking capabilities.
Autonomous operation without external systems
Web-Based Programming (VTC)
Visual Task Control with web-based programming. Easily develop task processing by combining icons for conditional branching and data output operations.
Icon-based programming interface
Cost Reduction & Increased Uptime
Operating ratios are boosted and unnecessary costs are reduced. Inspection costs are reduced through continuous monitoring without disassembly.
Eliminates disassembly inspection costs
Versatile Application Range
Applied to pumps, compressors, A/C fans, metalworking machines, and transport equipment. Suitable for water treatment, factory equipment, and building systems.
Wide industrial equipment compatibility
CPS-MM-LC combines continuous monitoring, predictive analytics, and autonomous IoT operation to eliminate unexpected motor failures while reducing maintenance costs and production downtime.
Continuous Monitoring Data Flow
From motor operation to cloud analytics: See how CPS-MM-LC processes real-time insulation data with edge computing, local storage, and optional cloud transmission
Data Flow Architecture
Complete data flow from motor to cloud showing edge processing (CPS-MM-LC), local storage (M2M Controller), web HMI access, and optional cloud transmission with offline resilience
Edge Processing
CPS-MM-LC performs real-time ADC conversion, resistance calculation, and threshold monitoring at 0.001mA resolution without sending data to external servers
Local Storage
M2M Controller provides circular buffer database for days-weeks of trend data with web HMI access via factory LAN. Fully autonomous operation without PC or cloud
Offline Resilience
Automatic network detection with exponential backoff retry logic. Local queue management ensures zero data loss during internet outages with auto-sync when connection restores
Complete Technical Specifications
Detailed specifications for CPS-MM-LC Motor Insulation Monitoring Module
Measurement Specifications
| Number of measurement channels | 1ch |
| Circuit to be measured | Power supply mode: Power output section Inverter mode: Inverter measurement Inverter mode: AC servo amplifier output measurement |
| ZCT inside diameter | φ25mm |
| Measurement time | 30 seconds |
Electrical Specifications
| Measured voltage range | Line to Line voltage: 10 VAC to 600 VAC |
| Measured leakage current range (resolution: 0.001mA) | Overall equipment measurement: 0 to less than 1A |
| Overall equipment measurement (Inverter output section) | 0 to less than 100 mA |
| Overall equipment measurement (AC servo amplifier output) | 0 to less than 100 mA |
Insulation Resistance
| Measured insulation resistance range | Less Than 1,000 MΩ |
| Accuracy specification range | Less than 10 MΩ |
Accuracy Specifications
| Line voltage accuracy | ±(1 percent of reading + 300 digits) |
| Leakage current Io accuracy | ±(1 percent of reading + 10 digits) |
| Leakage current Ior accuracy | ±(1 percent of reading + 10 digits + Io × 0.005) |
| Isolation resistance accuracy (at 25°C±2°C) | ±(10 percent of reading + 100 digits) when Io=Ior |
Motor Support
| Motor power support | Up to 30 kW |
| Pressure type | Low-pressure |
| Phase | Three-phase |
| Connection types supported | Three-phase delta connections and Three-phase Y connections |
System Requirements
| Required component | M2M controller CPU module (used in combination) |
| Supported devices | Inverters and AC servo amplifiers that supply low-voltage, three-phase power |
| Not supported | DC servo motors and equipment that use single-phase power supply |
Physical Specifications
| Dimensions (W×D×H) | 25.2 × 94.7 × 124.8 mm |
| Weight | 200g (module) / 600g (ZCT unit) |
| Installation method | Quick mounting on 35mm DIN rail |
| Connector | 2-piece 7.62mm pitch 4-pin terminal (AWG24-12) |
| LED indicators | Status (Green, Red) |
Power & Electrical
| Power voltage | 24VDC ±10 percent |
| Power consumption | 0.1A (Maximum) |
| Bus specification | CONPROSYS stack bus |
| Bus isolation voltage resistance | 2200VAC |
Environmental Specifications
| Operating temperature | -20 to +60°C |
| Storage temperature | -20 to +60°C |
| Humidity | 10 to 90 percent RH (no condensation) |
| Altitude | 2000m or less |
| Pollution degree | 2 |
| Measurement category | CAT III 300V / CAT II 600V |
Noise & Vibration Resistance
| Line noise resistance | ±1kV (IEC61000-4-4 Level 3) |
| Static electricity (contact discharge) | ±4kV (IEC61000-4-2 Level 2) |
| Static electricity (air discharge) | ±8kV (IEC61000-4-2 Level 3) |
| Vibration resistance | 10-57Hz / 0.15mm, 57-150Hz / 2.0G |
| Shock resistance | 15G half-sine shock for 11ms (IEC 60068-2-27) |
ZCT Unit Specifications
| Structure | Penetrating type |
| Rated voltage | 600VAC |
| Penetrating hole diameter | φ25mm |
| Cable length | 2.9m |
| Connector | ZER-11V-S (or equivalent) |
| Dimensions (W×D×H) | 37.2 × 74.5 × 115.9 mm |
| Weight | 600g |
| Installation | With screws (not for vibration/shock environments) |
System Configuration Limits
| Maximum modules per controller | Up to 16 modules |
| Module allocation | One CPS-MM-LC required per motor |
| Total current limit | 3.3A or less for entire configuration |
| Configuration type | Stackable design on DIN rail |
Software Ecosystem
| Visual Task Control (VTC) | Built-in script function for monitoring screen creation |
| CONPROSYS HMI | Screen creation function for custom interfaces |
| Script100 Sample Programs | Ready-to-use monitoring programs available for download |
| Customization support | Email notifications at thresholds, audible alerts, custom logic |
| Web browser configuration | All settings accessible via web interface - no specialized software required |
Custom ZCT Requirements
If you need a ZCT with diameter larger than 25mm, please contact us for custom solutions.
System Integration Required
This module must be used in combination with an M2M controller CPU module. See CONTEC website for details on M2M controller functions.
Industrial Applications & Use Cases
CPS-MM-LC motor insulation monitor serves diverse industries requiring continuous motor health monitoring and predictive maintenance
Water Treatment Facilities
Typical Equipment:
- Water supply pumps
- Drainage pumps
- Water treatment plants
- Water management systems
Benefit: Continuous monitoring ensures reliable water supply and treatment operations without unexpected pump failures
Factory Equipment
Typical Equipment:
- Production machinery motors
- Manufacturing equipment
- Assembly line motors
Benefit: Predictive maintenance reduces production downtime and increases equipment operating ratios
Parking Structures
Typical Equipment:
- Ventilation fan motors
- Lighting control systems
- Access control motors
Benefit: Ensures continuous operation of critical building safety and ventilation systems
Building Pump Equipment
Typical Equipment:
- HVAC circulation pumps
- Heating system pumps
- Cooling system pumps
Benefit: Maintains building comfort systems through proactive motor health monitoring
Water Supply Pumps
Typical Equipment:
- Municipal water distribution
- Pressure boosting pumps
- Supply network pumps
Benefit: Protects critical infrastructure with continuous insulation monitoring during operation
Drainage Pumps
Typical Equipment:
- Wastewater pumps
- Storm water management
- Sewage pumps
Benefit: Prevents environmental compliance issues through reliable drainage system operation
Transport Devices
Typical Equipment:
- Conveyor belt motors
- Material handling systems
- Automated transport equipment
Benefit: Ensures production line continuity by monitoring transport system motor health
Exhaust Devices
Typical Equipment:
- Industrial exhaust fans
- Ventilation systems
- Fume extraction motors
Benefit: Maintains environmental control and worker safety through continuous fan motor monitoring
Industrial Equipment
Typical Equipment:
- Compressors
- A/C fans
- Metalworking machines
- Painting booths
- Stirring devices
Benefit: Wide range of industrial motor applications supported with versatile monitoring capabilities
Industry Application Matrix
Visual overview of CPS-MM-LC deployment across 6 major industries with 15+ equipment categories
Industry Application Matrix
Visual overview of CPS-MM-LC insulation monitor deployment across 6 major industries: Water Treatment Facilities, Factory Equipment, Building Systems, Transport & Material Handling, Exhaust & Ventilation, and Specialized Equipment. Shows 15+ equipment categories including water supply pumps, production machinery, HVAC systems, conveyor motors, exhaust fans, painting booths, and more.
Critical Infrastructure
Protects municipal water systems, drainage pumps, and treatment facilities from unexpected motor failures affecting public services
Production Continuity
Ensures assembly lines, conveyor systems, and manufacturing equipment operate reliably through predictive maintenance strategies
Environmental Compliance
Maintains exhaust systems, ventilation fans, and environmental control equipment for worker safety and regulatory compliance
Installation Guide & System Setup
Four-step installation process for CPS-MM-LC motor insulation monitoring module
Step 1
Install ZCT Sensor
Mount φ25mm ZCT (Zero Current Transformer) sensor on motor cables. Position according to measurement mode: power supply mode (measurement point E) or inverter mode (inverter/servo output).
Tasks:
- Route motor cables through ZCT opening
- Secure ZCT sensor in position
- Verify proper cable alignment
Step 2
Connect to M2M Controller
Connect CPS-MM-LC module to M2M controller CPU module. This module must be used in combination with an M2M controller CPU module (sold separately).
Tasks:
- Connect module to M2M controller CPU
- Verify power supply connections
- Check electrical connections
Step 3
Configure Measurement Mode
Select appropriate measurement mode: Power Supply Mode (power output section measurement point E) or Inverter Mode (inverter/AC servo amplifier output measurement).
Tasks:
- Select Power Supply Mode or Inverter Mode
- Configure voltage range (10-600 VAC)
- Set leakage current monitoring parameters
Step 4
System Integration (Optional)
Configure web monitoring and cloud connectivity if required. Note: Autonomous device does not require PC or cloud connection for operation.
Tasks:
- Set up web monitoring interface (optional)
- Configure cloud connectivity (optional)
- Program Visual Task Control (VTC) if needed
Complete Wiring Configuration
System wiring from power source to motor with ZCT sensor placement, M2M controller integration, and optional cloud connectivity
Wiring Configuration Diagram
Complete system wiring showing power supply (10-600 VAC three-phase), NFB protection device, optional inverter/AC servo amplifier, three-phase motor (up to 30kW), φ25mm ZCT sensor installation, CPS-MM-LC module connection to M2M controller CPU, local web browser access via factory LAN, and optional cloud connectivity (MQTT/HTTP). Shows both Power Supply Mode (measurement point E) and Inverter Mode configurations.
Power Connections
Three-phase input (10-600 VAC line to line), NFB protection device recommended, supports delta and Y motor connections
ZCT Sensor Placement
Pass motor cables through φ25mm ZCT opening, position at measurement point E (power supply mode) or inverter output (inverter mode)
Controller Integration
Connect CPS-MM-LC to M2M controller CPU (mandatory), local web access via factory LAN, optional cloud connectivity (MQTT/HTTP)
Important Safety & Compatibility Notes
DC servo motors and single-phase power equipment are not supported
Contact manufacturer if ZCT diameter larger than 25mm is required
Supports inverters and AC servo amplifiers with low-voltage, three-phase power
M2M Controller CPU Module Required
This module must be used in combination with an M2M controller CPU module (sold separately). For details on M2M controller CPU module functions, see CONTEC website.
Frequently Asked Questions
Common technical questions about CPS-MM-LC motor insulation monitoring
Still have questions?
Contact your regional CONTEC office for technical consultation and detailed product information.
Ready to Implement Predictive Motor Maintenance?
Contact CONTEC for technical consultation, product information, and M2M controller compatibility details
Autonomous operation without PC or cloud required
Global technical support network
Compatible with M2M controller ecosystem
Continuous monitoring without equipment shutdown
Global Technical Support Network
Contact your regional CONTEC office for technical assistance
Trusted by water treatment facilities, factory equipment operators, and building systems managers for continuous motor health monitoring