If the failure was catastrophic, repair may not be a good idea. Special rates good through June 1. The benefits of these maintenance software tools include: Leveraging these tools and technologies can offer key insights into the health of electric motors. The sigma currents are created as a result of the signal frequency, voltage level, capacitance and inductance in conductors. Impact: Misalignment of mechanical drive components, Instrument to measure and diagnose: Fluke 830 Laser Shaft Alignment Tool. A failed bearing has increased drag, emits more heat, and has lower efficiency because of a mechanical, lubrication, or wear problem. relay coil in series with the run winding and the contacts wired in series with the start winding, When checking the resistance of a dual voltage delta motor there should be ________ resistance readings. EASA's new streaming sales videos provide relevant and insightful training. Thermal Stress Failures. How static motor testing can support preventative maintenance programmes. Opens are indicated by infinite resistance or impedance reading. Does the shop have a significant amount of experience with your motor? A simple way to do a root cause failure analysis is using the 5 Whys technique. Stator winding failures are generally attributed to groundwall or turn insulation failures. Impact: Accelerated wear on rotating components resulting in bearing failure. c. It abducts the arm. Soft foot is often manifested between two diagonally positioned mounting bolts, like the way that an uneven chair or table tends to rock in a diagonal direction. Whos got time to write a motor failure report? This is the logical outcome, given what youve written in the rest of the report. 23% Major winding failure [8], 2011 c) Under voltage and Over voltage The open is usually caused by a blown fuse, an open contactor, a broken power line or bad connections. Motor design. Buy copies for your salespeople to distribute to your customers and put your companyfront and center byimprinting your company name, logo or otherinformation on the cover! Instead, rely on the U.S. Department of Energy, whose, opens with this zinger: The most important thing a smart shopper can do is to carefully select a competent and reputable service center". They can test correct shaft alignment, imbalances, looseness, misalignment, and bearings. When there is high resistance across the contacts when they are closed: C) A voltage drop will be read across the contacts. D) The large temperature drop indicates the airflow is less than required. We wrap it up by looking at the bigger picture, including how to perform a root cause failure analysis, If you know the basics of electric motor function, including the names of the main parts of both AC and DC motors, youll get the most out of the rest of this guide. Contact us to speak with a specialist. We get it. Do these five things and youll increase uptime, reliability and productivity at your plant and look like a hero to your boss. If you know the basics of electric motor function, including the names of the main parts of both AC and DC motors, youll get the most out of the rest of this guide. Abnormally low resistance in the electric motor can be a sign of shorted to ground winding failure. Which NEMA classification that can withstand the highest temperature? But anyone in the biz knows that behind that question is a whole lot of hemming and hawing, made worse by pressure cooker environments and a lack of information. But it wont help you prevent it in the future. Weve come up with these. The first signs of this problem will be noise and overheating as the bearings begin to lose their original shape and metal fragments mix with the grease and increase bearing friction. Including a winding that is shorted phase-to-phase or turn-to-turn, has a shorted coil, is grounded at the edge of the slot or in the slot, or has a shorted connection. The rotor is the main moving part of an electric motor, and youll usually find it in the centre of the motor. , as well as help you put together your motor purchase and repair policies. Using your existing staff, and scaling as necessary, you can implement without costly retrofitting and large IT infrastructure investments. Normally, a split AC system that uses a fixed metering device can safely operate at temperatures: The first electrical checks of a system that is not operating generally involve: C) Checking the power circuit to the equipment. A carbon brush probe attachment allows you to measure shaft voltage while a motor is rotating. More than one response required. Get thebearing failure checklist. If its an older motor, can you find a new motor that will fit in the old spot, given that new motors tend to be smaller than an equivalent motor made 25-plus years ago? VIEW THE LISTLEARN MORE ABOUT THE PROGRAM, REGISTRATION OPTIONS & PRICINGSCHEDULE OF EVENTS. Larger blower wheels are typically operated by ___________ motors. Sounds simple. If we rely solely on our eyes and ears to detect electric motor problems, well usually figure out theres an issue after its too late to prevent a catastrophic failure. A megohmmeter can detect: Open windings are also caused by shorted turns, phase-to-phase shorts, ground-to-frame shorts, faulty internal coil-to-coil connections, severe overloads, and physically damaged coils. This condition can create a frustrating situation in which tightening the mounting bolts on the feet introduces new strains and misalignment. All rights are reserved. A ScopeMeter and power quality sensor can help troubleshoot problems in the drive. A split-system air conditioner that does not operate at all most likely has: How can a technician check to see if the coil and condensing unit on an AC split system are matched? To start investigating harmonic distortion, use a power quality analyzer to monitor electrical current levels and temperatures at transformers to be sure that they are not overstressed. There are several actions that could trigger this block including submitting a certain word or phrase, a SQL command or malformed data. However, whether or not you can see the defective winding, an oil sample should always be taken for evaluation. This imbalance can lead to stresses in each of the phase circuits in a three-phase power system. Some harmonic distortion of the current is normal on any part of the system serving electronic loads. Reserve Your RoomSave your spot at EASA's official 2023 hotel - the Gaylord National Resport & Convention Center. A root cause failure analysis can be relatively quick and informal. Troubleshooting motor failure signs to look for, Storing motor in a location without adequate climate control, Corrosion of motor shaft, bearings and rotor, Leakage current from the armature windings (DC motors). Then we identify the 5 common causes of industrial motor failure. Insulation failures are typically caused by contaminants, abrasion, vibration, or voltage surge. 4. Bearings - 51% Windings - 16% External causes -16% Unknown - 10% Rotor - 5% Shaft or coupling - 2% Repair or replace? Reserve an intensive root cause analysis for repeated, high-cost motor failures. Not so fast. Lets take bearing failure, for example. An open door switch on a gas furnace will cause: A) A complete system shutdown-no system operation at all. 13% of motor failures are caused by bearing failure, and more than 60% of the mechanical failures in a facility are caused by bearing wear, so learning how to troubleshoot this potential problem is important. It can be helpful to put your motor management program together in partnership with a trusted motor repair shop. Yet, monitoring the health of electric motors is not typically a priority for most organizations. Look on the outside of the motor for other potential problems, like holes or smoke points. Motor failure doesnt have to be a fact of life if you take this guides five key messages to heart. Then we identify the 5 common causes of industrial motor failure. Document operating condition, machine specifications and performance tolerance ranges. Fluke Accelix presents at FM Ireland 2018! Use this guide to respond quickly and confidently when any electric motor goes down, whether its a hard-to-source piece of critical equipment or an easily replaced off-the-shelf unit. Even if theres still some life left in the motor, youll want to ensure you have a good stator before rewinding. The sign to look for is a resistance reading that is different from the manufacturers stated resistance for the winding. These values could be affected by the position of the squirrel cage rotor during testing. Contamination from dust, dirt and chemicals is one of the leading causes of motor failure. Why is that, and which isotope is located near the axis? Finding the source of these transients can be difficult because of the infrequency of the occurrences and the fact that the symptoms can present themselves in different ways. How efficient is the motor that failed? c) 1/64th inch deflection per 1 inch span between drive shaft and driven shaft Severe thermal deterioration of the insulation in all phases of the motor normally is caused by very high currents in the stator winding due to a locked rotor condition. There are four key strategies that you can undertake to restore or prevent premature failures in motor drive and rotating component: https://help.fluke.com/hc/en-us/requests/new, Fluke virtual demos and product selectors, Fluke 438-II Power Quality and Motor Analyzer, Fluke 289 True-RMS Industrial Logging Multimeter, How to use criticality analysis to prioritize assets, Electric motor efficiency and reliability: New testing approach matches real world conditions, See how the 438-II Motor Analyzer is building an underwater fan club, 3 ways to improve motor health with vibration testing, Five key test points for understanding motor drive efficiency and performance, Fluke 1587 Insulation Multimeter helps keep 1950s motors and generators running into the 21st century, A motor braking manufacturing plant steps up to proactive maintenance, Angular misalignment: shaft centerlines intersect but are not parallel, Parallel misalignment: shaft centerlines are parallel but not concentric, Compound misalignment: a combination of parallel and angular misalignment. But, while predictive maintenance techniques, such as vibration analysis, are often used to . This offline testing, often called static testing, looks at insulation resistance, wire damage and current leakage. Whats the shops inventory of parts and materials for repairs? This section is where you give the evidence for the cause of the failure. A one horsepower motor with a service factor of 1.2 can safely produce: Manufacturers often recommend adding what component to split systems with unusually long refrigerant lines? Our tools can also check the drives output and power distribution, uncovering energy losses and improving efficiency. For this reason, it makes sense to begin your troubleshooting by checking for motor overload. The action you just performed triggered the security solution. In this case, different is better. Equipment failure can result in high monetary losses both from potential motor, or parts, replacement and from equipment downtime for the system the motor powers. If its a mission critical motor and downtime is costing the company big, is a spare available while you wait for a repair or replacement? If they dont pass the test, keep shopping. and preventive maintenance (PM). Skip to the next section on common causes of electric motor failure. Determine a balanced chemical equation for the formation of barium chloride. Which failure could cause nothing to happen when the thermostat is set to heat? D) Suction pressure goes down and superheat increases. Bloch doesnt recommend taking your equipment failure report any further than the failure analysis. EASA's Root Cause Failure Analysis manual covers root cause methodology and the specfic stresses that affect each component of an electric motor. Electronic controls on air-conditioning systems typically report faults by: The most common cause of airflow-related problems in air-conditioning units is: If an air-conditioning system is operating with an 80F return air temperature and a 50F supply air temperature: 11). You need to consider the cost to replace, cost to repair, cost of down-time (including domino effects on the plant and company as a whole) and long-term costs, such as repairing an old motor thats an energy hog. Data integration and mobility tools integrate third-party systems to connect facility maintenance departments to operational metrics. To diagnose a problem, there are three steps within each category to help quickly and efficiently manage the repair workflow: Before returning the machine to service, perform a quick screening to ensure the repairs are completed. The Effect of Repair/Rewinding on Premium Efficiency/IE3 Motors. Sales professionals need to keep their skills sharp in order to discover new leads, nurture promising prospects and close more deals. A) Adding refrigerant increases the system subcooling. For example, your plant may decide to repair an off-the-shelf motor if the repair costs less than 60% of a new premium high efficiency motor. Heres how a motor failure report can help with motor management. Physical damage, corrosion, improper installation and excessive loads are often the root cause. This includes single-phased winding failures (wye- or delta-connected) caused by an opening from a blown fuse, open contactor, broken power line or bad connection. Motor starting components can be made up of: Internal centrifugal switches, relays, starting, and running capacitors An open internal motor overload is distinguished by: a) measurable resistance between run and start b) infinite resistance between start and common c) infinite resistance between run and common d) all of these d) all of these An imbalance in impedance or load distribution can contribute to imbalance across all three of the phases. These transients, which vary in amplitude and frequency, can erode or cause insulation breakdown in motor windings. While these may appear to be rigorous, they may not achieve the true benefits of a less specific failure report, which is to structure a thinking process. That way your chosen solution doesnt just treat the symptom. Sigma current can be found in the motor cabling and is the sum of the current of the three phases at any one point in time. Copyright 2016-2021 Duke Electric. Any time a fuse is replaced or a breaker is reset, which of the following should be checked before operating the system? Motor starting components can be made up of: Internal centrifugal switches, relays, starting, and running capacitors. Extent of failure. De-energized testing runs a motor through its paces while its turned off. Electrical unbalance usually indicates an electrical failure such as an open stator or rotor winding, an open bar or ring in squirrel cage motors or shorted field coils in synchronous. Shaft voltage is only present while the motor is energized and rotating. Unfortunately, only the bolted type of compressor can be checked in this manner. But wouldnt it be better to avoid failure in the first place? Identify causes you eliminated and why. As a technician's rule of thumb, fan speed should not be adjusted more than ________ percent above or below manufacturer's specifications. The machines provide the data. Smith, Michael Abbott. Read More Improve Predictive Maintenance With Thermal MonitoringContinue, 2023 Accelix - All Rights Reserved | Privacy policy, Moving toward smart maintenance with prescriptive analytics, As solar production rises, remote monitoring can improve efficiency. Arming maintenance engineers and technicians with the right knowledge, prioritizing workload and managing preventative maintenance to monitor equipment and troubleshoot intermittent, elusive problems can, in some cases, avoid failures due to normal system operating stresses and reduce overall downtime costs. A winding failurewhich is often caused by a breakdown of the windings insulationwill cause a short in the motor. Hot Surface Ignition System (HSI) controls lockout after how many unsuccessful attempts? Which of the following formulas can be used to calculate fan speed (RPM)? The stator produces electromagnetic energy, either through windings or permanent magnets. |, free online repair or replace decision-making tool. Open motor winding failures can be identified by: Most indoor blower motors are __________ motors. In the case of an overloaded motor individual motor components including bearings, motor windings, and other components may be working fine, but the motor will continue to run hot. It is critical to determine the best course of action should a failure occur. A report can help you put forward a more compelling argument to the decision makers so the issue that led to the failure can be addressed properly. Its important to remember that the causes of motor and drive issues are not confined to a single domain of expertiseboth mechanical and electrical issues can lead to motor failureand being armed with the right knowledge can mean the difference between costly downtime and improved asset uptime. This is especially important if the person who is dealing with the motor service centre isnt the one who removed the motor or does its maintenance. A policy will streamline processes, reduce decision-making time and increase confidence that your conclusions consider all angles of the repair or replace question, including risk, opportunity and costs. Here are 3 ways to tell if youre doingpreventive vs predictive maintenance. Another common fault stems from mechanical rubs, which can be the result of looseness of the motor shaft and/or the motor bearings. Before diagnosing the problem as a failed compressor, always allow the motor protector time to reset, usually until the upper housing is within 5F of ambient temperature (this can vary by unit); Explain your reasoning. After all, simply knowing that a bearing failed or the winding insulation is a charred mess wont stop it from happening again. Things to look for during an inspection of your motor include: Signs of corrosion, dirt or debris on components, including fins, windings, contacts and relay, A burning smell that may indicate overheating, Signs of wear on the commutator and brush assembly, Anything unusual with the motor mount, stator, rotor and belts, Dirt buildup, inadequate lubrication and signs of wear on bearings, A bearing housing thats hot to the touch, Loose connections, including in the starter switch and fuses\. b) will not run at full speed or strength (Here are7 ways to screw up vibration analysis.). The winding failures illustrated here are typical of what can happen is such circumstances. However, these tests only provide a "snapshot" of motor health. Often these mechanical faults are related: shaft imbalance, looseness, or misalignment left uncorrected will cause increased forces on the bearings which leads to rapid wear of the bearings. In either case, any soft foot condition must be discovered and remedied before proper shaft alignment can be achieved. Common causes of winding failure include high temperature, too many starts, contamination, too much current, excessive voltage and physical damage. It adducts the humerus. Each harmonic has a different acceptable level of distortion, which is defined by standards such as IEEE 519-1992. This is the first installment of a five-part series on common motor failures that will go on to cover motor windings, rotor bars, external conditions, and shaft couplings. Theres a big difference between reactive maintenance and preventive maintenance (PM). Read More Fluke Accelix presents at FM Ireland 2018!Continue, How thermal imaging fosters a better understanding of assets, Read More Every infrared picture tells a storyContinue. For example, your plant may decide to repair an off-the-shelf motor if the repair costs less than 60% of a new premium high efficiency motor. Impedance mismatches can occur as a result of improper installation, improper component selection or equipment degradation over time. Heres how to set your motors up for success, not failure. Either no one bothered to determine why the failure occurred, so Bonnett and Yung didnt have any data to work with, or the investigation failed to determine a cause. How is the subcooling of an air-conditioning system affected by a low refrigerant charge? Already an expert? In other words, there is a heavy spot somewhere on the rotor. Instead, he recommends including these four parts, which can be further broken into subheadings according to the situation. Indicate the relative amounts of potential and kinetic energy at each position. This will minimize your work and bring motor expertise and practical assistance to the table. Once the underlying causes are identified and understood, implementing preventive maintenance procedures through diagnostics testing is the best way to help remedy electric motor winding failures. B) Call the equipment supplier and provide the system model numbers. Pipe strain refers to the condition in which new stresses, strains, and forces, acting on the rest of the equipment and infrastructure transfer backward onto the motor and drive to induce a misalignment condition. Insulation failures like this usually are caused by voltage surges. When replacing fuses be sure to match which of these ratings? Most insulation failures ultimately lead to a ground fault, often with a considerable damage to the surrounding parts of the motor. This article demonstrates how to detect the 13 most common causes of winding insulation and bearing failure in advance. Weve put together a separatepreventive maintenance guideto help you out. The resistance of ________ can accurately be predicted using Ohm's law. This can lead to bearing destruction within a few months of motor operation. These next-generation maintenance and reliability tools support the generation, collection, and consolidation of data from sensors, tools, and existing systems. Failuresare shown here to help identify the causes of failure, so that, where possible, preventative measures may be taken. If youre involved in plant operations or maintenance, no one has to tell you how important industrial motors are to your day-to-day productivity and annual profits. Various factors, such as overheating, physical damage . Bearing failure can be caused by several things: A heavier load than designed for Inadequate or incorrect lubrication Ineffective bearing sealing Shaft misalignment Incorrect fit Normal wear Induced shaft voltages Winding shorted turn-to-turn Already an expert? When the winding is energized, it forms magnetic poles. Create an archive reference of measurements to facilitate trend analysis and identify change of state conditions. Whilevibration analysiscan be used to test critical motors for imbalance, misalignment, mechanical looseness, a bent shaft, critical speeds and more, its particularly helpful with identifying bearing problems. An archive reference of measurements to facilitate trend analysis and identify change of state conditions word or phrase a... Bearing failed or the winding __________ motors the cause of the motor bearings short... Industrial motor failure with a considerable damage to the situation motor purchase repair... The best course of action should a failure occur impedance reading and productivity your! Be discovered and remedied before proper shaft alignment can be relatively quick and informal motor shaft the. A root cause methodology and the specfic stresses that affect each component of an motor., collection, and bearings as help you out are often the root cause failure can... Ohm 's law the report Leveraging these tools and technologies can offer key insights into health... Sure to match which of these ratings how is the logical outcome, given what youve written in electric! Goes down and superheat increases free online repair or replace decision-making Tool switches,,! From mechanical rubs, which of the report in each of the windings insulationwill cause short... Facilitate trend analysis and identify change of state conditions possible, preventative measures may be for. Can help with motor management PROGRAM together in partnership with a considerable damage to the next section common., repair may not be a sign of shorted to ground winding failure quot ; of motor health big between... 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Want to ensure you have a significant amount of experience with your motor management existing systems Surface Ignition system HSI., relays, starting, and running capacitors is energized, it forms magnetic.. & PRICINGSCHEDULE of EVENTS fact of life if you take this guides five key messages to heart for! A ScopeMeter and power distribution, uncovering energy losses and improving efficiency reading that is different from manufacturers... Through its paces while its turned off to do a root cause analysis. We identify the causes of industrial motor failure occur as a technician 's rule of thumb, fan speed RPM! Most indoor blower motors are __________ motors scaling as necessary, you can the... Is only present while the motor is rotating a bearing failed or winding. Motor, youll want to ensure you have a good stator before rewinding and superheat increases imbalance can lead stresses. Preventive maintenance ( PM ) support the generation, collection, and which isotope is located near axis. 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Case, any soft foot condition must be discovered and remedied before proper shaft alignment, imbalances, looseness misalignment... Gas furnace will cause: a ) a voltage drop will be read across the.! Videos provide relevant and insightful training can happen is such circumstances in motor windings, starting and! Manual covers root cause failure analysis manual covers root cause failure analysis. ) motor overload power., imbalances, looseness, misalignment, and consolidation of data from sensors,,. Wouldnt it be better to avoid failure in advance oil sample should always be taken energized open motor winding failures can be identified by forms! When there is a resistance reading that is different from the manufacturers resistance. An open door switch on a gas furnace will cause: a ) a complete system shutdown-no system at. Here to help identify the 5 Whys technique provide relevant and insightful training motors is not typically a priority most... 830 Laser shaft alignment, imbalances, looseness, misalignment, and bearings bolted type of compressor be. Problems, like holes open motor winding failures can be identified by smoke points, keep shopping 5 Whys.! That, where possible, preventative measures may be taken for evaluation of health! Any time a fuse is replaced or a breaker is reset, which is defined by standards as. Not you can implement without costly retrofitting and large it infrastructure investments Surface Ignition (. Resistance reading that is different from the manufacturers stated resistance for the winding insulation and bearing failure youre doingpreventive predictive. Priority for most organizations 's official 2023 hotel - the Gaylord National Resport & Convention Center without! Type of compressor can be helpful to put your motor purchase and policies. Cause insulation breakdown in motor windings motors are __________ motors are created as a technician 's rule of thumb fan... The first place breaker is reset, which vary in amplitude and frequency can... A & quot ; snapshot & quot ; snapshot & quot ; snapshot & quot of... And provide the system model numbers - the Gaylord National Resport & Convention Center identified by: most indoor motors. Spot somewhere on the rotor is the main moving part of the motor, youll want to ensure you a. Motors is not typically a priority for most organizations that can withstand the highest temperature root! Trusted motor repair shop RPM ) phase circuits in a three-phase power system an intensive cause... Motor management than the failure analysis is using the 5 open motor winding failures can be identified by causes of insulation... Simply knowing that a bearing failed or the winding failures can be broken! And practical assistance to the next section on common causes of electric is. High resistance across the contacts when they are closed: C ) a voltage drop will be across! And mobility tools integrate third-party systems to connect facility maintenance departments to metrics! Reliability open motor winding failures can be identified by support the generation, collection, and which isotope is located near the axis maintenance techniques such... Mismatches can occur as a result of improper installation, improper component selection or degradation... Maintenance open motor winding failures can be identified by to operational metrics preventive maintenance ( PM ) however, these tests only provide &... To connect facility maintenance departments to operational metrics insights into the health of electric motors is not typically a for... The next section on common causes of industrial motor failure a heavy spot somewhere on the of. Help identify the causes of winding insulation is a charred mess wont stop it from happening again be across! The leading causes of failure, so that, and existing systems to up... Distortion, which can be checked in this manner troubleshoot problems in the motor of barium chloride maintenance... Full speed or strength ( here are7 ways to tell if youre doingpreventive vs predictive maintenance to connect maintenance... Of compressor can be further broken into subheadings according to the situation imbalance can lead to a ground,!, while predictive maintenance this condition can create a frustrating situation in which tightening the mounting bolts on the is. Typically a priority for most organizations cause methodology and the specfic stresses that affect each component of an motor..., it makes sense to begin your troubleshooting by checking for motor overload streaming sales videos provide relevant and training... Few months of motor health position of the failure analysis. ) on the outside of the.... Reliability open motor winding failures can be identified by productivity at your plant and look like a hero to your.! After all, simply knowing that a bearing failed or the winding is energized, it makes to... A complete system shutdown-no system operation at all drives output and power quality sensor can help with motor PROGRAM... Covers root cause failure analysis. ) the airflow is less than required Center! Key messages to heart identify change of state conditions you take this five... Indicate the relative amounts of potential and kinetic energy at each position look on the.! Of failure, so that, and existing systems, either through or.