The open is usually caused by a blown fuse, an open contactor, a broken power line or bad connections. Organize the content under subheadings that make sense. Even if theres still some life left in the motor, youll want to ensure you have a good stator before rewinding. 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. We've put together a post onwinding failure, with awesome photos courtesy of EASA, if you're looking for examples. Hot Surface Ignition System (HSI) controls lockout after how many unsuccessful attempts? Lets take bearing failure, for example. Determine a balanced chemical equation for the formation of barium chloride. In DC motors, the commutator is a switch that reverses the direction of the electrical current to keep the rotor spinning. The primary symptoms that accompany a motor overload are excessive current draw, insufficient torque and overheating. This will help you identify patterns with a particular asset and make warranties easy to manage. 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. Nearly all air conditioning condenser fans are ________ motors. Why doesn't uranium ore spontaneously undergo a chain reaction? For this reason, it makes sense to begin your troubleshooting by checking for motor overload. But it can also come from your own team if you arent involving a shop, or provide additional support for the shops recommendations. Document operating condition, machine specifications and performance tolerance ranges. Look on the outside of the motor for other potential problems, like holes or smoke points. An open internal motor overload is distinguished by: Motors that sit on resilient rubber rings typically use which type of mounting? Then we identify the 5 common causes of industrial motor failure. A brush assembly is often used to shift the current. Improve Predictive Maintenance With Thermal Monitoring, Quick Start: Fluke Connect Handheld Tools, Quick Start: Fluke 1742/1746/1748 Three-Phase Power Quality Loggers, causes of electric motor winding failures, Computerized Maintenance Management System (CMMS). 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. This makes the perfect handout for your employees! The imagers test faulty connections, overheated bearings, and tank levels. 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. 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. 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. The suction pressure on a split AC system that is running with an excessive evaporator heat load: The manufacturer's data on a split AC system indicates that the normal temperature drop should be 15F at the current operating conditions. Here are some of the more common motor tests to perform regularly as part of your early warning system. 1 in 10 failures are mysterious. Insulation issues can be the result of unequal voltage between phases due to unbalanced loads on the power source, a poor connection at the motor terminal, or high resistance contact. The correct tension for any belt drive application is: When thats not possiblewhen internal resources are stretched or a repair is too complex, for exampleits critical to choose your motor repair shop carefully. We get it. It can be helpful to put your motor management program together in partnership with a trusted motor repair shop. 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. The stator is the stationary part of the motor. A ScopeMeter and power quality sensor can help troubleshoot problems in the drive. But if youre honest, how much of your time is spent firefighting instead of focusing on your to-do list? These losses dissipate in the form of heat, which, over time, will deteriorate the insulation capability of the windings. Impact: Misalignment of mechanical drive components, Instrument to measure and diagnose: Fluke 830 Laser Shaft Alignment Tool. Please include what you were doing when this page came up and the Cloudflare Ray ID found at the bottom of this page. Some motor shops offer their customers a24/7 online motor management systemto help them keep track of their assets, including maintenance and repair histories. Plant managers seeking to maintain motor uptime, engineers who rely on precise data to monitor asset health, and maintenance managers trying to stay a step ahead of motor failures can access data. Gives a bottom-line summary of the essential information in the report in approximately 100 words. Oil analysis can be used to check on sleeve bearings that have oil reservoirs. Maintenance software and data gathering devices that integrate with third-party solution providers are ideal to accomplish this. Note:Under-voltage and over-voltage (exceedingNEMAstandards) will result in the same type of insulation deterioration. Do you need OEM parts or can your motor shop fabricate or source OEM-enhanced parts? Do these five things and youll increase uptime, reliability and productivity at your plant and look like a hero to your boss. 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. You can email the site owner to let them know you were blocked. 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. What term expresses the ability of the motor to work beyond its rated output? From live engineering support to technical training and resources, EASA offers the solutions you need to elevate your business! Once acid is identified in In either case, any soft foot condition must be discovered and remedied before proper shaft alignment can be achieved. | Site Design & Development by Human_Code. Instrument to measure and diagnose: Fluke 810 Vibration Tester. 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. Here are 3 ways to tell if youre doingpreventive vs predictive maintenance. And so on. When troubleshooting split air conditioning systems be sure to check voltage to: Which of these methods used to determine which component in a circuit is not working properly? A clean, climate-controlled, organized shop makes it easier to work efficiently and take proper care of the motors that are in for repair. Vertical mount fan motors require ________ to handle the force of the shaft pushing against the end bells of the motor. Leveraging these tools offers facilities the greatest flexibility and power to manage the health of electric motor windings. 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. Weve come up with these 6 questions to ask deciding whether to repair or replace your electric motor. Butdont screw it up. A method of measuring voltage across each component moving toward the malfunctioning load is called: The resistance of an AC magnetic device will have ________ resistance than Ohm's law predicts. 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. We can see your eyes rolling. These next-generation maintenance and reliability tools support the generation, collection, and consolidation of data from sensors, tools, and existing systems. Sales professionals need to keep their skills sharp in order to discover new leads, nurture promising prospects and close more deals. In other words, there is a heavy spot somewhere on the rotor. 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. The ________ is used to identify all the controls in series with the load. 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. A one horsepower motor with a service factor of 1.2 can safely produce: On PSC multi-speed indoor blowers the wire that is wired to power regardless of speed is the ________ wire. An open winding falls into which general motor failure area? Explain why a sample of iron(III) sulfate is uncharged. 4. That way you can save your bearing next time, instead of simply having it fail again. On PSC multi-speed indoor blowers the wire that is wired to power regardless of speed is the ________ wire. But wouldnt it be better to avoid failure in the first place? By continually asking why, youll get a deeper understanding of what happened. However, if the motor is more than 10 years old and less than 1 HP, the motor is usually replaced. Root cause failure analysis(RCFA) is a well-documented process for examining a failed motor and its system. This section is where you give the evidence for the cause of the failure. The motor and insulation tester assure safe operation, prolongs the life of electrical systems and motors. Open motor winding failures can be identified by: A) Zero resistance reading B) Infinite resistance reading C) Measurable resistance reading D) All of the above B) Infinite resistance reading Motor starting components can be made up of: A) Starting and running capacitors only B) Internal and external centrifugal switches only B) The temperature difference between the coil operating temperature and the air passing over the coil. 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. Chances are, you arent the final decision maker on larger operational and capital expenditures. D) After the draft switch closes to prove the draft. Need an Accredited service center?Find a service center that has proven they repair electric motors in accordance with ANSI/EASA's AR100. Other failures are caused by vibration, physical damage and situations that causes excessive heat. How long will it take to get the motor repaired? Here is a list of the common winding problems found in an electric motor: Shorted to ground winding failure. Motors are rated in either ________ or ________ operation. 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. It raises the clavicle. Voltage surges are often the result of switching power circuits, lightning strikes, capacitor discharges and solid-state power devices. Acid test kits and sight glasses help to identify a system contaminated by moisture and acid. The questions are based on these four criteria. a) contamination A) International Electrotechnical Commission (IEC). A single-phased winding failure is the result of an open in one phase of the power supply to the motor. Contamination. Which failure could cause nothing to happen when the thermostat is set to heat? How static motor testing can support preventative maintenance programmes. See more information related to AC and DC Windings in EASA's Resource Library. 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. . When an electric motor fails, theres one question that must be answered. Will the shop do the work themselves, or will they outsource it? If the failure was catastrophic, repair may not be a good idea. 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. Where you give the evidence for the formation of barium chloride strikes, capacitor discharges and solid-state power.! Shift the current sit on resilient rubber rings typically use which type of insulation deterioration power supply to the,. Fan motors require ________ to handle the force of the motor mechanical drive components, Instrument to and. Simply having it fail again test kits and sight glasses help to identify a system contaminated moisture. 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For the shops recommendations motor overload are excessive current draw, insufficient torque and overheating will deteriorate insulation...
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