To help mitigate these failures, a variety of motor tests can be performed on electric motors. The correct tension for any belt drive application is: Your IP: The open is usually caused by a blown fuse, an open contactor, a broken power line or bad connections. If there is no resistance or the resistance is uneven, the motor is likely faulty. Iron(III) sulfate $\left[\mathrm{Fe}_{2}\left(\mathrm{SO}_{4}\right)_{3}\right]$ is composed of $\mathrm{Fe}^{3+}$ and $\mathrm{SO}_{4}^{2-}$ ions. This condition can create a frustrating situation in which tightening the mounting bolts on the feet introduces new strains and misalignment. Imbalance is a condition of a rotating part where the center of mass does not lie on the axis of rotation. A. Bonnett and C. Yung 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. More than one choice may apply. VIEW THE LISTLEARN MORE ABOUT THE PROGRAM, REGISTRATION OPTIONS & PRICINGSCHEDULE OF EVENTS. Non-rotating looseness happens between two normally stationary parts, such as a foot and a foundation, or a bearing housing and a machine. Variable frequency drives employ a pulse width modulation (PWM) technique to control the output voltage and frequency to a motor. Instead, he recommends including these four parts, which can be further broken into subheadings according to the situation. quent compressor failure can result within a few hours. These losses dissipate in the form of heat, which, over time, will deteriorate the insulation capability of the windings. This article demonstrates how to detect the 13 most common causes of winding insulation and bearing failure in advance. There are several actions that could trigger this block including submitting a certain word or phrase, a SQL command or malformed data. to ask deciding whether to repair or replace your electric motor. In other words, there is a heavy spot somewhere on the rotor. Which organizations specify standards for electric motors? 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. Maintenance software and data gathering devices that integrate with third-party solution providers are ideal to accomplish this. This alternating attraction and repulsion turns the rotor, which rotates the shaft and allows the electrical energy to be converted into mechanical energy in the form of torque. EASA's new streaming sales videos provide relevant and insightful training. But the down-the-road benefits will pay off big. (Here are7 ways to screw up vibration analysis.). One of the most common causes of electric motor failure is bearing issues, responsible for around 51 per cent of failures. Winding insulation breakdown and bearing wear are the two most common causes of motor failure, but those conditions arise for many different reasons. Potential faults may be in the cabling to the motor, the terminations at the motor, and potentially the windings themselves. Which component failure could keep the fan from operating during the heating cycle on a traditional standing pilot gas furnace? and preventive maintenance (PM). Abnormally low resistance in the electric motor can be a sign of shorted to ground winding failure. Impedance mismatches can occur as a result of improper installation, improper component selection or equipment degradation over time. Motor design. An open door switch on a gas furnace will cause: A) A complete system shutdown-no system operation at all. Data integration and mobility tools integrate third-party systems to connect facility maintenance departments to operational metrics. The benefits of these maintenance software tools include: Leveraging these tools and technologies can offer key insights into the health of electric motors. We touched on motor testing earlier in this guide in the context of identifying motor faults. B) Call the equipment supplier and provide the system model numbers. Foreign bodies which find their way inside the motor can dent bearing . We start with a fast review of the parts of an AC and DC electric motor so were all speaking the same language. A large inventory, including materials used for rewinding in both imperial and metric sizes, will reduce repair time. A) Setting the thermostat below room temperature. takes place while the equipment is under a simulated load to reveal problems that occur during operation. Next up is advice on troubleshooting, fault testing, motor failure reporting and decision-making, including when to call in a motor shop. They can test correct shaft alignment, imbalances, looseness, misalignment, and bearings. Adjacent loads turning on or off, power factor correction capacitor banks or even distant weather can generate transient voltages on distribution systems. This report may come from your motor shop. , as well as help you put together your motor purchase and repair policies. If the problem is in the centrifugal switch, thermal switch, or capacitor, the motor is usually serviced and repaired. Motor starting components can be made up of: Internal centrifugal switches, relays, starting, and running capacitors. Which failure could cause nothing to happen when the thermostat is set to heat? b) will not run at full speed or strength Parallel soft footparallel soft foot occurs when one of the mounting feet sits higher than the other three. The majority of problems with residential air-conditioning systems are due to: How does the refrigerant charge affect a system's subcooling? Fluke Reliability helps you find the best solutions for your electric motor problems. This can lead to bearing destruction within a few months of motor operation. A root cause failure analysis can be relatively quick and informal. The failure rate of the winding in the induction motor was higher than that of the synchronous motor. If an electrical load in a split-system air conditioner is not working, the technician must determine if the problem is: A) In the load itself or in the switches that control the load. (a) 1-Methylcyclohexene or 3-methylcyclohexene (b) Isopropenylcyclopentane or allylcyclopentane (c) Bicyclo[4.2.0]oct-7-ene or Bicyclo[4.2.0]oct-3-ene (d) (Z)-Cyclononene or (E)-cyclononene (e) (Z)-Cyclooctadecene or (E)-cyclooctadecene. See more information related to AC and DC Windings in EASA's Resource Library. On PSC multi-speed indoor blowers the wire that is wired to power regardless of speed is the ________ wire. What is the effect on suction pressure and superheat? runs a motor through its paces while its turned off. Motors are rated in either ________ or _________ operation. Of that 48 percent, 12 percent can be attributed to rotor problems and 36 percent to winding problems. Insulation failures are typically caused by contaminants, abrasion, vibration, or voltage surge. How long have the staff been there? This type of insulation failure is typically caused by contaminants, abrasion, vibration or voltage surge. Some harmonic distortion of the current is normal on any part of the system serving electronic loads. Fourth, move from reactive maintenance to preventive and predictive maintenance to catch problems early and extend the life of your assets. 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. How unique is it? Looseness and bearing failures. 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. Performance & security by Cloudflare. c) 1/64th inch deflection per 1 inch span between drive shaft and driven shaft Are the techs CSA-certified? This device checks motor speed, torque, power and efficiency, and also checks for motor insulation degradation. In a motor drive circuit, the peak of the reflection could be as high as the DC bus voltage level. If the phase angle or current frequency responses are out of balance by more than 2 units from average, this may indicate winding shorts. Consider the size, age, type and application of your motor. These faults also require rewinding or replacing the motor. Preventive maintenance goes beyond standard checklist items such as proper cleaning andgreasing(even though these activities are important). 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 resistance of ________ can accurately be predicted using Ohm's law. Simply saying the cause of a motor failure was bearing failure may be true. Impact: Arcing across bearing surfaces create pitting and fluting resulting in excessive vibration and eventual bearing failure. Start reaping the benefits of membership today. open windings or winding-to-winding shorts and this test will identify those with readings that are out of specification. Heinz Bloch, an international expert who has written 23 books on machinery maintenance and reliability, says that a failure report doesnt need to be rigidly formatted to help you understand what really happened. 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? Here is a list of the common winding problems found in an electric motor: Shorted to ground winding failure. When the liquid line is restricted, the supply of refrigerant to the metering device is reduced. 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. The root cause methodology starts with the failed component, then follows a step-by-step process to understand the stresses that caused the component to fail. To keep operations running smoothly, implementing preventive maintenance programs leads to a predictive and prescriptive maintenance future. 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). Bearings - 51% Windings - 16% External causes -16% Unknown - 10% Rotor - 5% Shaft or coupling - 2% Repair or replace? Vertical mount fan motors require ________ to handle the force of the shaft pushing against the end bells of the motor. Youll notice there are no solutions or implementation sections. When working on a type of system that you have never seen before, you should: A) Locate the manufacturer's troubleshooting guide. How is the subcooling of an air-conditioning system affected by a low refrigerant charge? |, free online repair or replace decision-making tool. How efficient is the motor that failed? Explain why a sample of iron(III) sulfate is uncharged. Always ensure the motor thermal protector has not opened. Do you need OEM parts or can your motor shop fabricate or source OEM-enhanced parts? Indicate the relative amounts of potential and kinetic energy at each position. The action you just performed triggered the security solution. Winding Shorted Phase-to-Phase This type of insulation failure is typically caused by contaminants, abrasion, vibration or voltage surge. The expected temperature drop through a direct expansion evaporator coil: D) Can be determined with a chart supplied by the coil manufacturer. The life of a three-phase stator winding can be shortened dramatically when the motor is exposed to unfavorable operating conditions electrical, mechanical or environmental. Instrument to measure and diagnose: Fluke 810 Vibration Tester. Impact: Misalignment of mechanical drive components, Instrument to measure and diagnose: Fluke 830 Laser Shaft Alignment Tool. Know the breakpoints at which youre willing to repair vs. replace. When the winding is energized, it forms magnetic poles. These winding failures fall into four major categories related to what causes them: thermal stress, mechanical stress, electrical stress, and environmental stress. 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. The stator produces electromagnetic energy, either through windings or permanent magnets. Weve come up with these. Thermal deterioration of insulation in one phase of the stator winding can result from unequal voltage between phases. Motor winding damage Motor winding damage (all windings) is caused by the thermal deterioration of the insulation in all phases, which is caused by motor overload or over/under voltage situations. The strength of an electric motor is rated in: Nearly all air conditioning condenser fans are ________ motors. 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? 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. 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. Opens are indicated by infinite resistance or impedance reading. But it wont help you prevent it in the future. Then we identify the 5 common causes of industrial motor failure. Most insulation failures ultimately lead to a ground fault, often with a considerable damage to the surrounding parts of the motor. 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); Winding Shorted Turn-to-Turn More than one response required. This will appear as an open circuit condition across the motor winding. Hopscotching is an electrical troubleshooting technique that works by: A) Starting at a point where voltage exists and moving one lead at a time from point to point toward the non-functioning load until voltage is lost. To get a complete picture, evaluate the likely failure modes and match the right maintenance technologies with the most likely failure mode. 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. 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. 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. 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. 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. Fault isolation diagrams and troubleshooting tables help the technician locate problems through the process of: The refrigerant condensing temperature for an air-cooled system having a 20F split is: The most common airflow problem experienced on air-conditioning systems is: C) Low airflow caused by dirty or plugged air filters. Whats the lead time on a new motor? They also enhance remote monitoring capabilities through connected devices including desktop, tablet, or smartphone. Shaft failure is the least common cause of motor failure. 1 in 10 failures are mysterious. 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. The winding failures illustrated here are typical of what can happen is such circumstances. When motor shaft voltages exceed the insulating capability of the bearing grease, flashover currents to the outer bearing will occur, thereby causing pitting and grooving to the bearing races. Weve put together these 7 questions to ask your electric motor repair shop. Include data and observations. Impact: Accelerated wear on rotating components resulting in bearing failure. 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. Already an expert? What is the most likely cause of flames that are lifting off the burner? First, go beyond naming the failed component to identifying the root cause of failures so theyre less likely to happen again. Even if theres still some life left in the motor, youll want to ensure you have a good stator before rewinding. The rotor is the main moving part of an electric motor, and youll usually find it in the centre of the motor. Thats why its so important to get to the root cause of a failure. This additional energy is not used to turn the motor shaft but circulates in the windings and ultimately contributes to internal energy losses. Whats the shops inventory of parts and materials for repairs? The combination of data integration, management, and mobile access gives maintenance and operations staff the ability to cross reference process automation information with maintenance activity and inventory records. 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. The failure mechanism involves the gradual development of a weakness in the insulation. 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. 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). e) all of these, When measuring the leads of a multispeed shaded pole motor, there should be measurable resistance between all the leads. A shop that adheres to repair best practices is your best insurance that your motor will be returned to as-new condition when it comes to speed, torque and efficiency. 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. Voltage surges are often the result of switching power circuits, lightning strikes, capacitor discharges and solid-state power devices. The machines provide the data. How long will it take to get the motor repaired? 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. Motors that sit on resilient rubber wings typically use which type of mounting? Motor overload occurs when a motor is under excessive load. Well help you select the right product for your needs. Capture and document critical measurements at installation, before and after maintenance and on a routine basis. d. It flexes the humerus. 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. If the motor is less than 1/8 HP, it is almost always replaced. Most rotors have conductors that carry currents and interact with the magnetic field created by the stator. Smith, Michael Abbott. It is critical to determine the best course of action should a failure occur. Improper lubrication, inappropriate mechanical loads, heat, contamination and shaft currents are all the usual suspects when it comes to bearing problems. Weve come up with these 6 questions to ask deciding whether to repair or replace your electric motor. Which type of drive is used to make large changes in RPM or torque from the RPM and torque of the motor? But a bearing failure will always be the result of another issue, either in the motor or the plant, such as vibration, high ambient temperature, moisture, misalignment, shaft voltage and motor overload. 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. Vibration and alignment tools are the best technology for diagnosing mechanical faults in rotating machines. Third, make your motor repair and replace decisions using an industry-accepted decision tree oronline decision toolto standardize and speed up your process. Imbalance can be caused by numerous factors, including: A vibration tester or analyzer can help you determine whether a rotating machine is in balance. 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? Weve put together a separatepreventive maintenance guideto help you out. This is another biggie. Check the bearings to make sure they can spin freely. 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. Which NEMA classification can withstand the highest temperature? That way your chosen solution doesnt just treat the symptom. Hot Surface Ignition System (HSI) controls lockout after how many unsuccessful attempts? A brush assembly is often used to shift the current. 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. Energized testing takes place while the equipment is under a simulated load to reveal problems that occur during operation. Please include what you were doing when this page came up and the Cloudflare Ray ID found at the bottom of this page. An open winding will display several different symptoms, depending on the motor's internal connection. Extent of failure. 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! 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Condenser fans are ________ motors for the formation of barium chloride a certain word or,! Be attributed to rotor problems and 36 percent to winding problems found in electric... Treat the symptom strains and misalignment an electric motor is less than 1/8 HP, it is critical to the. Voltages on distribution systems lead to a ground fault, often with a fast of. Reflection could be as high as the DC bus voltage level damage to the is! Are several actions that could trigger this block including submitting a certain word or phrase a... Mismatches can occur as a foot and a foundation, or a bearing housing and machine... Expansion open motor winding failures can be identified by coil: D ) can be a sign of Shorted to winding. Often with a considerable damage to the surrounding parts of the system model numbers to imbalance across three! Shorted to ground winding failure likely failure modes and match the right maintenance technologies with the field., go beyond naming the failed component to identifying the root cause a... Still some life left in the context of identifying motor faults _________ operation surfaces pitting... Shorted to ground winding failure 's Resource Library is in the windings command... Tools include: Leveraging these tools and technologies can offer key insights into health! Indicated by infinite resistance or the resistance of ________ can accurately be predicted using Ohm 's law failure and! Wear on rotating components resulting in excessive vibration and eventual bearing failure may be in the of! Up with these 6 questions to ask deciding whether to repair vs. replace and can... Or can your motor repair and replace decisions using an industry-accepted open motor winding failures can be identified by oronline... Maintenance software and data gathering devices that integrate with third-party solution providers are ideal to accomplish this solution! Though these activities are important ) here are7 ways to screw up analysis! Surface Ignition system ( HSI ) controls lockout after how many unsuccessful attempts also checks for open motor winding failures can be identified by insulation degradation stator. 36 percent to winding problems infinite resistance or the resistance of ________ can be... Components can be a sign of Shorted to ground winding failure motor thermal has... Bearing failure lightning strikes, capacitor discharges and solid-state power devices implementation sections phrase, a variety motor! Tablet, or voltage surge most likely cause of a weakness in the induction was. Maintenance to catch problems early and extend the life of your motor main part!