If the failure was catastrophic, repair may not be a good idea. By continually asking why, youll get a deeper understanding of what happened. Prescriptive maintenance is the next big step forward in the evolution of asset management, Read More Moving toward smart maintenance with prescriptive analyticsContinue, Read More As solar production rises, remote monitoring can improve efficiencyContinue, Dave OReilly, VP of Commercial, Fluke Corporation, offers a sneak peek of our upcoming webinar, Read More Why you should integrate your dataContinue. Is it well suited for the application, or is it time to spec a new motor that can better accomplish what your process demands? The correct tension for any belt drive application is: D) All of the these are indicators of correct tension. 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. Thermal Stress Failures. Yet determining the cause is a critical step in protecting your motors. Your IP: With the motor running, you can perform dynamic testing to identify issues with temperature, balance and distortion. A Weibull-shaped parameter in the range of [ 20 ] 2.8-3.0 was used to describe bearing failures and indicated an increasing failure rate and worn-out . Here is a list of the common winding problems found in an electric motor: Shorted to ground winding failure. Others will need more than five. 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. 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. When is the gas valve energized on an induced-draft furnace that uses hot surface ignition? Motors are rated in either ________ or _________ operation. This section is where you give the evidence for the cause of the failure. Keep all of your organizations assets up and running without downtime. The failure rate of the winding in the induction motor was higher than that of the synchronous motor. 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. If the phase angle or current frequency responses are out of balance by more than 2 units from average, this may indicate winding shorts. EASA's new streaming sales videos provide relevant and insightful training. 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: Third, make your motor repair and replace decisions using an industry-accepted decision tree oronline decision toolto standardize and speed up your process. Special rates good through June 1. 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. Instead of answering a bunch of questions from the motor shopwhich may require digging up information or recalling events from days or weeks agoyou hand the guys a report. EASA-validated. Use the following chart to connect the dots between electric motor problems, causes, effects (which are often invisible until the motor fails and is dismantled at a motor shop) and signs to look for that could help you take early action. 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. This offline testing, often called static testing, looks at insulation resistance, wire damage and current leakage. If the failure was catastrophic, repair may not be a good idea. You can identify early signs of motor trouble by performing ongoing monitoring of motor health. A winding failurewhich is often caused by a breakdown of the windings insulationwill cause a short in the motor. Foreign bodies which find their way inside the motor can dent bearing . and preventive maintenance (PM). Its one thing to identify the component thats failed and another thing to isolate the cause of that component failure. Weve put together these 7 questions to ask your electric motor repair shop. When is the induced draft blower energized on an induced-draft furnace that uses hot surface ignition? Some harmonic distortion of the current is normal on any part of the system serving electronic loads. Are you interested in learning more about how to determine the true cause of an electric motor failure? Any time a fuse is replaced or a breaker is reset, which of the following should be checked before operating the system? Leveraging these tools offers facilities the greatest flexibility and power to manage the health of electric motor windings. More than one response required. Which of the following formulas can be used to calculate fan speed (RPM)? A megohm test, also known as amegger test, is one of the most frequently performed tests for insulation strength, thanks to its simplicity, but its best to combine it with other motor insulation tests. 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. It is found that one isotope is more concentrated near the axis of rotation of the chamber and the other is more concentrated near the cylindrical wall of the chamber. Unfortunately, only the bolted type of compressor can be checked in this manner. This will minimize your work and bring motor expertise and practical assistance to the table. d) all of these are indicators of correct tension, d) all of these are indicators of correct tension. 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). 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. Winding contamination cannot always be readily identified as the root cause of an insulation failure. Heres an example of the 5 Whys in action. Identify causes you eliminated and why. A simple motor failure decision tree can form the foundation of a plants motor failure policy. Know the breakpoints at which youre willing to repair vs. replace. This report may come from your motor shop. We can see your eyes rolling. Its responsible for 51% of motor failures. We've turned EASA's decision tree into a free online repair or replace decision-making tool to give you a repair or replace answer right away. to ask deciding whether to repair or replace your electric motor. Windings are made from insulated metal wire, usually copper but sometimes aluminum, that are laid in coils and wound around either the rotor or the stator. If writing the odd report meant you could spend more of your time getting sh*t done instead of fixing stuff that broke when it wasnt supposed to, would you be willing to give it a try? Only recently have they come together to make predictive inspection methods, portable condition monitoring, remote control and monitoring, and SaaS Computerized Maintenance Management System (CMMS) available and cost-effective. Note:Under-voltage and over-voltage (exceedingNEMAstandards) will result in the same type of insulation deterioration. Many professionals believe that a flexible coupling eliminates and compensates for misalignment, but a flexible coupling only protects the coupling from misalignment. 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. However, whether or not you can see the defective winding, an oil sample should always be taken for evaluation. It adducts the humerus. These next-generation maintenance and reliability tools support the generation, collection, and consolidation of data from sensors, tools, and existing systems. PM has been shown to reduce downtime by as much as 50%. A few methods can detect such issues, including, for one, surge-partial-discharge testing, during which investigators look for the repetitive partial-discharge inception voltage (RPDIV) and repetitive partial-discharge extinction voltage (RPDEV), and impulse value in millivolts (mV). Which organizations specify standards for electric motors? near the wall? Non-rotating looseness happens between two normally stationary parts, such as a foot and a foundation, or a bearing housing and a machine. 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. 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. Most insulation failures ultimately lead to a ground fault, often with a considerable damage to the surrounding parts of the motor. Motor failure doesnt have to be a fact of life if you take this guides five key messages to heart. Some plants prefer to perform their own motor repairs. Contamination from dust, dirt and chemicals is one of the leading causes of motor failure. You can identify dead shorts, loose connections and open circuits in coiled windings using a digital multimeter. Next up is advice on troubleshooting, fault testing, motor failure reporting and decision-making, including when to call in a motor shop. A common cause of an open winding is undersized lead lugs. Need an Accredited service center?Find a service center that has proven they repair electric motors in accordance with ANSI/EASA's AR100. Open motor winding failures can be identified by: Most indoor blower motors are __________ motors. And those issues will have another cause. D) Suction pressure goes down and superheat increases. 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. If there is no resistance or the resistance is uneven, the motor is likely faulty. Even with a flexible coupling, a misaligned shaft will transmit damaging cyclical forces along the shaft and into the motor, leading to excess wear on the motor and increasing the apparent mechanical load. It can also be a process that takes several months and proceeds systematically through all six steps, perhaps with external support from a consultant or experienced motor shop. Choose the more stable alkene in each of the following pairs. Common air conditioning controls are switches that open or close based on a monitored condition such as: After determining that a high pressure switch is open, the next step is to: A high resistance problem can be detected by. Simply stated, harmonics are any unwanted additional source of high frequency AC voltages or currents supplying energy to the motor windings. The open is usually caused by a blown fuse, an open contactor, a broken power line or bad connections. Reproduction of these photographs by print or electronic means is prohibited. Sounds simple. Transient voltages can come from several sources either inside or outside of the plant. Impact: Imbalance creates excessive current flow in one or more phases that then increases operating temperaturesleading to insulation breakdown. It treats the underlying condition that created the situation in the first place. Lack of secondary air or a stopped up vent will cause: When is the igniter energized on an induced draft furnace that uses hot surface ignition? Weve hinted at the need to take a systematic, big-picture approach to your electric motors, but heres where we stop beating around the bush: if you want to prevent motor failure, put a total motor management program in place at your plant. This space between the rotor and stator is sized specifically to ensure proper interaction between magnetic fields and optimal performance of the motor. With predictive maintenance, tasks are less about keeping to a schedule and more about performing them on an as-needed basis. d) can be detected by comparing the actual winding resistance to the motor manufacturer's data Winding Shorted Phase-to-Phase This type of insulation failure is typically caused by contaminants, abrasion, vibration or voltage surge. Excessive motor heat is a major cause of motor failure. An open internal motor overload is distinguished by: The RPM of a belt driven blower can be determined by: Multiplying motor RPM and motor sheave diameter and then divide by the fan sheave diameter, When checking the resistance of a dual voltage wye motor, there should be ______ resistance readings. Although you can never eliminate motor imbalance, you can identify when it is out of normal range and act to rectify the problem. Why is that, and which isotope is located near the axis? Motor control systems are being utilized in critical processes throughout manufacturing plants. Maintenance teams can cost-effectively implement this technology platform to address their needs with ease. How unique is it? Design is critical to the repair-replace decision. Our tools can also check the drives output and power distribution, uncovering energy losses and improving efficiency. Which NEMA classification that can withstand the highest temperature? 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. It is made of thin metal sheets, called laminations, instead of being solid, to reduce energy losses. Do they follow the ANSI/EASA AR100 best practices? A newly installed valve or another component, An object striking, bending, or simply pressing on a pipe, Broken or lack-of pipe hangers or wall-mounting hardware. When replacing fuses be sure to match which of these ratings? Infrared imagers are the best technology for finding electrical hot spots in switchgear and motor controllers, for the screening process and mechanical assets. Reflections are generated when there is an impedance mismatch between the source and load. Explain your reasoning. Given that early damage to a motor is usually subtle and hidden, motor testing is usually performed as part of regular preventive maintenance rather than when a motor is acting up. The strength of an electric motor is rated in: Nearly all air conditioning condenser fans are ________ motors. What is the first step in the operational sequence? 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. Bearings - 51% Windings - 16% External causes -16% Unknown - 10% Rotor - 5% Shaft or coupling - 2% Repair or replace? It may also occur as a result of excessive starts or reversals. Other failures are caused by vibration, physical damage and situations that causes excessive heat. Weve come up with these. Find out in less than 2 minutes. Everyone is busy. Winding shorted phase-to-phase This type of insulation failure is typically caused by contaminants, abrasion, vibration or voltage surg What is the most likely cause of flames that are lifting off the burner? All photographs are copyrighted 1985-2019byEASA. Possible solution: It is critical that the motor is kept as cool as possible, ensuring the operating environment is kept cool if possible will help prevent breakdowns. If not, you might not get the most qualified team or best price. We touched on motor testing earlier in this guide in the context of identifying motor faults. D) The large temperature drop indicates the airflow is less than required. The questions are based on these four criteria. 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. But if youre honest, how much of your time is spent firefighting instead of focusing on your to-do list? They can test correct shaft alignment, imbalances, looseness, misalignment, and bearings. Are the techs CSA-certified? These circulating currents can find their way through protective earth systems causing nuisance tripping or in some cases excess heat in windings. Copyright 2016-2021 Duke Electric. One of the most common causes of electric motor failure is bearing issues, responsible for around 51 per cent of failures. This will help you identify patterns with a particular asset and make warranties easy to manage. A) International Electrotechnical Commission (IEC). An open door switch on a gas furnace will cause: A) A complete system shutdown-no system operation at all. The sigma currents are created as a result of the signal frequency, voltage level, capacitance and inductance in conductors. Already an expert? Most rotors have conductors that carry currents and interact with the magnetic field created by the stator. When the liquid line is restricted, the supply of refrigerant to the metering device is reduced. Thats because a lot can be learned from a standardized reporting process. 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. 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. If the evaporator entering air temperature is 80F and the leaving air temperature is 55F, the technician knows that the system: B) Most likely has low air flow because of the higher-than-normal temperature drop. If the reading is infinite, your motor should be fine. Weve spent most of this guide talking about what to do when a motor fails. Reserve Your RoomSave your spot at EASA's official 2023 hotel - the Gaylord National Resport & Convention Center. Please include what you were doing when this page came up and the Cloudflare Ray ID found at the bottom of this page. After all, simply knowing that a bearing failed or the winding insulation is a charred mess wont stop it from happening again. To get there, you have to understand the underlying causes of motor failures. Your motor shop can help you identify critical assets,establish an online motor database, and store and maintain your spares, as well as help you put together your motor purchase and repair policies. When thats not possiblewhen internal resources are stretched or a repair is too complex, for exampleits critical to choose your motor repair shop carefully. Tied with windings for almost 1 in 5 motor failures, external factors include temperature, contamination, poor maintenance, inappropriate mechanical loads and events such as flooding. The most common mechanical faults are shaft imbalance, looseness, misalignment, and bearings. The knee-jerk conclusion about the cause of the motor failure is often very different from the conclusion a tech will reach after writing a formalized report. Whos got time to write a motor failure report? An open winding falls into which general motor failure area? It should concisely answer what, where, when, how and possibly why. This can lead to bearing destruction within a few months of motor operation. Each harmonic has a different acceptable level of distortion, which is defined by standards such as IEEE 519-1992. Then we identify the 5 common causes of industrial motor failure. Extent of failure. Electrical insulation is classified by the ________ stability of the materials that are used for the winding. That way, action can be taken before its too late. Instead, rely on the U.S. Department of Energy, whose Service Center Evaluation Guide opens with this zinger: The most important thing a smart shopper can do is to carefully select a competent and reputable service center". 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. We've put together a post onwinding failure, with awesome photos courtesy of EASA, if you're looking for examples. The imagers test faulty connections, overheated bearings, and tank levels. Located between the stator and rotor, bearings are used to keep the rotor centred and shrink the air gap. That way you can save your bearing next time, instead of simply having it fail again. All rights are reserved. 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. How to Test Your Spindle Motor for Short to Ground Set your multimeter to Ohms. Does the shop have experience with your motor? Smith, Michael Abbott. Here are 3 ways to tell if youre doingpreventive vs predictive maintenance. Which type of drive is used to make large changes in RPM or torque from the RPM and torque of the motor? Imbalance can be caused by numerous factors, including: A vibration tester or analyzer can help you determine whether a rotating machine is in balance. At the simplest level, all three phases of voltage should always have the same magnitude. c) 1/64th inch deflection per 1 inch span between drive shaft and driven shaft Cost. Electric motors serve as a critical component for any facility. 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\. The rotor is the main moving part of an electric motor, and youll usually find it in the centre of the motor. B) The temperature difference between the coil operating temperature and the air passing over the coil. Contamination. You can add these sections to your failure report if youre responsible for them at your plant, or you can leave them to the motor shop. Winding Shorted Turn-to-Turn Butdont screw it up. This article demonstrates how to detect the 13 most common causes of winding insulation and bearing failure in advance. Hot Surface Ignition System (HSI) controls lockout after how many unsuccessful attempts? These faults also require rewinding or replacing the motor. The failure mechanism involves the gradual development of a weakness in the insulation. In the motor if winding is open 33% Stator can induce more current causes winding failure, for creation of vibration rotor winding can fail. c) are hard to detect All of the failure modes were analysed utilising a Weibull cumulative distribution function. Impact: Premature wear on motor electrical and mechanical components leading to permanent failure, Instrument to measure and diagnose: Fluke Ti480 PRO Infrared Camera, Fluke 289 True-RMS Industrial Logging Multimeter. Fourth, move from reactive maintenance to preventive and predictive maintenance to catch problems early and extend the life of your assets. 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. The strength of an electric motor is rated in: The RPM of a belt driven blower can be determined by: B) Multiplying motor RPM and motor sheave diameter and then divide by the fan sheave diameter. However, its important to move toward predictive maintenance programs. See more information related to AC and DC Windings in EASA's Resource Library. Youll notice there are no solutions or implementation sections. B) Call the equipment supplier and provide the system model numbers. What is their internal quality management system and how do they make sure theyre following it? Impact: Motor winding insulation breakdown leads to unplanned downtime, Instrument to measure and diagnose: Fluke 190-204 ScopeMeter Test Tool, Fluke 1587 FC Insulation Multimeter. Preventive maintenance goes beyond standard checklist items such as proper cleaning andgreasing(even though these activities are important). However, electric motors can be prone to any number of issues that lead to motor faults and failures. Insulation failures are typically caused by contaminants, abrasion, vibration, or voltage surge. But the down-the-road benefits will pay off big. The structured process of report writing gets you to think more and differently about what happened. Rotating looseness is caused by excessive clearance between rotating and stationary elements of the machine, such as in a bearing. These winding failures fall into four major categories related to what causes them: thermal stress, mechanical stress, electrical stress, and environmental stress. Adding a little extra refrigerant over the amount recommended by the manufacturer: C) Reduces both system capacity and efficiency. Whats the shops inventory of parts and materials for repairs? Motor windings account for about 32% of all AC electric motor repairs. As a technician's rule of thumb, fan speed should not be adjusted more than ________ percent above or below manufacturer's specifications. The primary symptoms that accompany a motor overload are excessive current draw, insufficient torque and overheating. Opens are indicated by infinite resistance or impedance reading. Nearly half (48 percent) of all motor failures are due to electrical issues, according to a survey by the Electric Power Research Institute (EPRI). Second, formalize your documentation and reporting so its easy to get all the information about a particular motor to the people that need it. 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? 23% Major winding failure [8], 2011 c) Under voltage and Over voltage We get it. Failuresare shown here to help identify the causes of failure, so that, where possible, preventative measures may be taken. What you get:We start with a fast review of the parts of an AC and DC electric motor so were all speaking the same language. The way the information is communicated plays an important role in the way the situation is handled and decisions that are made, both for the motor in question and the entire fleet. Always ensure the motor thermal protector has not opened. famously compiled survey data and identified the five most common causes of electric motor failure, which can be linked to stresses related to normal operation as well as flukes. b) insulation faults Mark your calendars for FM Ireland and stop by Stand D10 to learn about the Accelix ecosystem of maintenance and reliability solutions. Insulation failures are typically caused by contaminants, abrasion, vibration, or voltage surge. 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Carry currents and interact with the magnetic field created by the manufacturer: ). The induced draft blower energized on an induced-draft furnace that uses hot surface ignition we get it failurewhich often... Is where you give the evidence for the winding together these 7 questions open motor winding failures can be identified by ask whether! Most insulation failures are typically caused by vibration, or voltage surge a ) a complete shutdown-no! Goes beyond standard checklist items such as a technician 's rule of thumb fan. Streaming sales videos provide relevant and insightful training how and possibly why 's! Looseness happens between two normally stationary parts, such as IEEE 519-1992 when the liquid is!