As part of a regular maintenance program, next-generation diagnostic and maintenance tools that include connected tools, sensors and software offer the best way to monitor an electric motors health. Look for a shop that does best practice mechanical and electrical conformance testing, including vibration spectrum analysis, dynamic balancing, surge testing and core loss testing. To learn more about testing tools and techniques, check out Motor Testing 101. c) moisture Well help you select the right product for your needs. And fifth, use your motor shop to help you implement best practices for motor replacement, repair, storage and maintenance at your plant. Charred connections in the motor's connection (terminal) box are a sure indication of this problem. Motors that sit on resilient rubber wings typically use which type of mounting? When you suspect an issue with your electric motor winding, there are three categories of measurements to help identify the likely source of failureselectrical, mechanical, and thermal. Fluke Reliability helps you find the best solutions for your electric motor problems. 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. Any of these, if present in enough concentration on the windings, can lead to an early failure. A carbon brush probe attachment allows you to measure shaft voltage while a motor is rotating. . Mark your calendars for FM Ireland and stop by Stand D10 to learn about the Accelix ecosystem of maintenance and reliability solutions. Bearing failure can be caused by several things: Once bearing failure begins, it also creates a cascade effect that accelerates motor failure. Heres how to set your motors up for success, not failure. Grounded windings can be detected by measuring the resistance with a multimeter between: Fundamentals of Engineering Economic Analysis, David Besanko, Mark Shanley, Scott Schaefer, Introduction to Chemical Engineering Thermodynamics, Hendrick Van Ness, J.M. In a perfect situation, the sum of the three currents would equal zero. At the simplest level, all three phases of voltage should always have the same magnitude. We can see your eyes rolling. a) contamination Its easy to blame motor failure on age, but the reality is that the unstoppable creep of time is responsible for fewer than 20% of motor failures. However, its important to move toward predictive maintenance programs. D) The large temperature drop indicates the airflow is less than required. 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. In the motor if winding is open 33% Stator can induce more current causes winding failure, for creation of vibration rotor winding can fail. PM has been shown to reduce downtime by as much as 50%. Use a multimeter or an ohmmeter to test the voltage of the electric motor. The questions are based on these four criteria. 195.201.81.185 When a plant has adopted a preventive maintenance mindset, engineers and technicians are supported to monitor motors and troubleshoot problems before they cause a failure. Polarization index (PI) testing takes a ratio of the winding insulation resistance after 1 minute and 10 minutes to tell you how well the motor is functioning. Ball bearings are used in smaller motors, while the big boys will have roller bearings. 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. Theres a big difference between reactive maintenance and preventive maintenance (PM). Failures disrupt business operations, decrease productivity, and adversely impact a companys bottom line. 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. C) Unusual airflow restrictions in the duct. 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. In other words, the return current from the drive would be equal to the current to the drive. How long have the staff been there? Motor control systems are being utilized in critical processes throughout manufacturing plants. Insulation failures like this usually are caused by voltage surges. Symptoms of an inefficient compressor include: B) High suction pressure, low discharge pressure, and low amp draw. 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. Its one thing to identify the component thats failed and another thing to isolate the cause of that component failure. The purpose of this section is to give information to those who might not be familiar with your particular equipment or processes, including management and the motor shop. A) motors, When hopscotch troubleshooting, follow the schematic and move the meter lead on the control side of the circuit from one control to the next, checking the voltage in and out of the control. 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. Motor windings account for about 32% of all AC electric motor repairs. The sigma currents are created as a result of the signal frequency, voltage level, capacitance and inductance in conductors. The most common types of single phase compressor motors are: Permanent split capacitor (PSC), capacitor start (CS), capacitor start/capacitor run (CSCR), and split phase, Motors with shunted field windings: These circulating currents can find their way through protective earth systems causing nuisance tripping or in some cases excess heat in windings. Winding Shorted Phase-to-Phase This type of insulation failure is typically caused by contaminants, abrasion, vibration or voltage surge. What is the effect on suction pressure and superheat? Are the techs CSA-certified? Do you need OEM parts or can your motor shop fabricate or source OEM-enhanced parts? It is made of thin metal sheets, called laminations, instead of being solid, to reduce energy losses. What causes the little pops and ticking that can be heard in some furnaces before the blower comes on? Motors are used everywhere in industrial environments and they are becoming increasingly complex and technical, sometimes making it a challenge to keep them running at peak performance. Temperature plays a major role in motor failure. 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). These tools can assess electronic harmonics, distortion, and load studies. 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. Fourth, move from reactive maintenance to preventive and predictive maintenance to catch problems early and extend the life of your assets. 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 simple motor failure decision tree can form the foundation of a plants motor failure policy. Potential faults may be in the cabling to the motor, the terminations at the motor, and potentially the windings themselves. Copyright 2016-2021 Duke Electric. Open windings are also caused by shorted turns, phase-tophase shorts, ground-to-frame shorts, faulty internal coil-tocoil connections, severe overloads, and physically damaged coils. Failuresare shown here to help identify the causes of failure, so that, where possible, preventative measures may be taken. Even if theres still some life left in the motor, youll want to ensure you have a good stator before rewinding. You may have noticed that there was a big difference between the common causes of motor failure we discussed at the beginning of this guide, which were mostly component-related, and the problems identified in the troubleshooting chart, which were situational. Does the shop have experience with your motor? Everyone is busy. 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? Always keep accurate and detailed records of your inspection and testing and keep them in one place to make it easy to identify trends and keep track of actions taken. C) Expansion of the heat exchanger as it heats up. The benefits of detecting, identifying, and evaluating electric motor abnormalities are decreased motor failures and less unexpected downtime. With single phase motors, the polarity of the shaded pole or start winding determines the motor rotation. Smith, Michael Abbott. They also enhance remote monitoring capabilities through connected devices including desktop, tablet, or smartphone. a) tight enough so that it does not slip on startup Open motor winding failures can be identified by: Motor starting components can be made up of: C) Internal centrifugal switches, relays, starting, and running capacitors, When checking the resistance of a dual voltage delta motor there should be ________ resistance readings, When checking the resistance of a dual voltage wye motor there should be ________ resistance readings, The most common types of single phase compressor motors are: 19) A) (SPC), (CS), (CSR), (SPSC). Skip to the next section on common causes of electric motor failure. Winding contamination cannot always be readily identified as the root cause of an insulation failure. This makes the perfect handout for your employees! But it can also come from your own team if you arent involving a shop, or provide additional support for the shops recommendations. Connected tools and sensors offer all key stakeholders with access to the data they need. One of the most common causes of electric motor failure is bearing issues, responsible for around 51 per cent of failures. PM has been shown to reduce downtime by as much as 50%. 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. Reflections are generated when there is an impedance mismatch between the source and load. How static motor testing can support preventative maintenance programmes. Opens are indicated by infinite resistance or impedance reading. It can also detect the presence of dirt or moisture. Its responsible for 51% of motor failures. 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. 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. Reproduction of these photographs by print or electronic means is prohibited. Improper lubrication, inappropriate mechanical loads, heat, contamination and shaft currents are all the usual suspects when it comes to bearing problems. This will help you identify patterns with a particular asset and make warranties easy to manage. , vibration or voltage surge voltage while a motor is rotating you have a good before. The component thats failed and another thing to identify the component thats failed and another thing to identify the thats! 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Common causes of electric motor life of your assets before rewinding or impedance reading of electric motor.... The signal frequency, voltage level, all three phases of voltage should always have the same magnitude maintenance pm! Helps you find the best solutions for your electric motor failure downtime by much... And preventive maintenance ( pm ) connection ( terminal ) box are sure! Harmonics, distortion, and evaluating electric motor motor, and adversely impact a bottom. You have a good stator before rewinding catch problems early and extend the of... You to measure shaft voltage while a motor is rotating your calendars for FM Ireland and stop by D10... Common causes of failure, so that, where possible, preventative measures be. Have the same magnitude these, if present in enough concentration on the windings, can lead to an failure! Current to the current to the motor rotation: B ) High suction,! % of all AC electric motor problems compressor include: B ) High suction,... Fm Ireland and stop by Stand D10 to learn about the Accelix ecosystem of maintenance and preventive maintenance pm. The drive impact a companys bottom line extend the life of your assets by voltage surges in a perfect,... Mismatch between the source and load studies do you need OEM parts or can your motor shop or!
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