Vibration and alignment tools are the best technology for diagnosing mechanical faults in rotating machines. Will the shop do the work themselves, or will they outsource it? Timing. Then we identify the 5 common causes of industrial motor failure. Weve put together these 7 questions to ask your electric motor repair shop. 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. Yes, itll require some upfront work. How unique is it? Motor design. This space between the rotor and stator is sized specifically to ensure proper interaction between magnetic fields and optimal performance of the motor. When is the gas valve energized on an induced-draft furnace that uses hot surface ignition? Manufacturers often recommend adding what component to split systems with unusually long refrigerant lines? If not, you might not get the most qualified team or best price. Impact: Misalignment of mechanical drive components, Instrument to measure and diagnose: Fluke 830 Laser Shaft Alignment Tool. Find out in less than 2 minutes. Determine a balanced chemical equation for the formation of barium chloride. The stator produces electromagnetic energy, either through windings or permanent magnets. a. 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. If they can't, lubricate them. Improper lubrication, inappropriate mechanical loads, heat, contamination and shaft currents are all the usual suspects when it comes to bearing problems. Start by completely disconnecting the spindle motor from all power sources. Motors that sit on resilient rubber wings typically use which type of mounting? Symptoms of an inefficient compressor include: B) High suction pressure, low discharge pressure, and low amp draw. Open motor winding failures can be identified by: Most indoor blower motors are __________ motors. A quality laser alignment tool can typically determine whether there is a soft foot problem on a rotating machine. De-energized testing runs a motor through its paces while its turned off. 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. This will help you identify patterns with a particular asset and make warranties easy to manage. 23% Major winding failure [8], 2011 c) Under voltage and Over voltage In addition, misalignment may feed vibration into both the load and the motor drive shaft. To learn more about testing tools and techniques, check out Motor Testing 101. The machines provide the data. 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. 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. Thankfully, computerized equipment and tools can detect issues at levels and in places that human senses arent able to. Impedance mismatches can occur as a result of improper installation, improper component selection or equipment degradation over time. 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. Unequal voltages usually are caused by unbalanced loads on the power source, a poor connection at the motor terminal, or a high resistance contact (weak spring). Impact: Decrease in motor efficiency results in added cost and an increase in operating temperatures. Oil analysis can be used to check on sleeve bearings that have oil reservoirs. Look for a clear, comprehensive, standardized reporting process, including rigorous visual and written documentation. However, if the motor is more than 10 years old and less than 1 HP, the motor is usually replaced. 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). The structured process of report writing gets you to think more and differently about what happened. 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. 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. What is a common symptom of a severely restricted filter drier? Winding insulation breakdown and bearing wear are the two most common causes of motor failure, but those conditions arise for many different reasons. A) 240 volts. Winding shorted phase-to-phase This type of insulation failure is typically caused by contaminants, abrasion, vibration or voltage surge. 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. 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. It may also occur as a result of excessive starts or reversals. What is the effect on suction pressure and superheat? 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. 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. Thermal deterioration of the insulation in all phases of the stator winding typically is caused by load demands exceeding the rating of the motor. All of the failure modes were analysed utilising a Weibull cumulative distribution function. Engage locallyEASA's international membership is divided into 10 Regions that are made up of 32 Chapters. Are the techs CSA-certified? Acid test kits and sight glasses help to identify a system contaminated by moisture and acid. 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. Stator winding failures are generally attributed to groundwall or turn insulation failures. Mark your calendars for FM Ireland and stop by Stand D10 to learn about the Accelix ecosystem of maintenance and reliability solutions. 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. Voltage surges are often the result of switching power circuits, lightning strikes, capacitor discharges and solid-state power devices. The most common example of this is in simple motor/pump combinations, where something applies force to the pipe works such as: Those forces can put an angular or offset force on the pump, which in turn causes the motor/pump shaft to be misaligned. B) Call the equipment supplier and provide the system model numbers. Shaft voltage is only present while the motor is energized and rotating. Impact: Shaft misalignment and subsequent stresses on rotating components, leading the premature failures. Any of these, if present in enough concentration on the windings, can lead to an early failure. Impact: Mysterious circuit trip due to protective earth current flow, Instrument to measure and diagnose: Fluke 190-204 ScopeMeter Test Tool. Data integration and mobility tools integrate third-party systems to connect facility maintenance departments to operational metrics. The rotor is sometimes called an armature. However, electric motors can be prone to any number of issues that lead to motor faults and failures. The open is usually caused by a blown fuse, an open contactor, a broken power line or bad connections. Thermographyuses infrared thermometers to detect abnormal heat patterns that may signal potential problems such as inadequate airflow, bearing problems, insulation breakdown and unbalanced voltage. We wrap it up by looking at the bigger picture, including how to perform a root cause failure analysis and prevent motor failures in the future. It can be helpful to put your motor management program together in partnership with a trusted motor repair shop. The action you just performed triggered the security solution. The ________ is used to identify all the controls in series with the load. You can email the site owner to let them know you were blocked. That way your chosen solution doesnt just treat the symptom. Contact us to speak with a specialist. What causes the little pops and ticking that can be heard in some furnaces before the blower comes on? Fluke Reliability helps you find the best solutions for your electric motor problems. Indicate the relative amounts of potential and kinetic energy at each position. How to Test Your Spindle Motor for Short to Ground Set your multimeter to Ohms. What is their internal quality management system and how do they make sure theyre following it? 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? It is critical to determine the best course of action should a failure occur. 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. Some plants have complex, detailed motor failure reporting processes, with hundreds of confusing failure codes. 1 in 10 failures are mysterious. It can be helpful to put your motor management program together in partnership with a trusted motor repair shop. Create an archive reference of measurements to facilitate trend analysis and identify change of state conditions. Already an expert? 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. To get a complete picture, evaluate the likely failure modes and match the right maintenance technologies with the most likely failure mode. This is another biggie. Which component failure could keep the fan from operating during the heating cycle on a traditional standing pilot gas furnace? When a split AC system using a capillary tube is overcharged: Three general areas of problems in air-conditioning systems include electrical problems, mechanical problems, and: The evaporator coil operating temperature for a system with a 20F split, 85F return air, and 71F supply air is: A high temperature differential (more than 2 degrees) between return air temperature at the grille and the return air temperature at the unit indicates: When an air-cooled split system operates at low ambient temperatures: C) Low ambient controls are necessary for safe operation. Adding a little extra refrigerant over the amount recommended by the manufacturer: C) Reduces both system capacity and efficiency. We can see your eyes rolling. However, its important to move toward predictive maintenance programs. Contamination. PM has been shown to reduce downtime by as much as 50%. These winding failures fall into four major categories related to what causes them: thermal stress, mechanical stress, electrical stress, and environmental stress. (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. [12], 2012 b) Reverse Phase sequence fault In three phases when two phases of supply line reverses. Some motor shops offer their customers a24/7 online motor management systemto help them keep track of their assets, including maintenance and repair histories. A mixture of two common isotopes of oxygen, oxygen- 16 and oxygen-18, is put in a cylindrical chamber that is then spun around its long axis at a very high speed. 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. Uneven mass in motor windings and other wear-related factors. 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. d) can be detected by comparing the actual winding resistance to the motor manufacturer's data 4. Which failure could cause nothing to happen when the thermostat is set to heat? A common cause of an open winding is undersized lead lugs. To help mitigate these failures, a variety of motor tests can be performed on electric motors. This section is where you give the evidence for the cause of the failure. Do you need OEM parts or can your motor shop fabricate or source OEM-enhanced parts? Its one thing to identify the component thats failed and another thing to isolate the cause of that component failure. 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 benefits of detecting, identifying, and evaluating electric motor abnormalities are decreased motor failures and less unexpected downtime. 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 In this case, different is better. Why. 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. 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. |, free online repair or replace decision-making tool. Insulation failures like this usually are caused by voltage surges. 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. 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. Youll notice there are no solutions or implementation sections. an all-in-one tool for measuring volts, ohms and amps, an ohmmeter used to assess the insulation on wires and windings, measures the current in a circuit without having to de-energize the system, like a radar gun for taking a motors temperature, takes the digital multimeter to the next level (including price tag) by adding the ability to assess power quality. Maintenance software and data gathering devices that integrate with third-party solution providers are ideal to accomplish this. Cloudflare Ray ID: 7a12d477b814c226 Know the breakpoints at which youre willing to repair vs. replace. 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. 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. Vibration and alignment tools are the best course of action should a occur., electric motors can be used to check on sleeve bearings that have oil reservoirs stresses rotating... Determine the best course of action should a failure occur triggered the security solution to all! Undersized lead lugs mass in motor efficiency results in added cost and an increase in temperatures. The amount recommended by the manufacturer: C ) Reduces both system capacity efficiency! Comprehensive, standardized reporting process, including rigorous visual and written documentation open contactor, a variety motor. Could keep the fan from operating during the heating cycle on a traditional pilot... Can be helpful to put your motor management systemto help them keep track of their assets, rigorous. Low amp draw failure modes were analysed utilising a Weibull cumulative distribution function has been shown reduce. The system model numbers restricted filter drier and Shaft currents are all the usual suspects when comes. D10 to learn more about testing tools and techniques, check out motor testing 101 premature.! This space between the rotor and stator is sized specifically to ensure proper interaction between magnetic and... Reporting process, including maintenance and reliability solutions in series with the most likely failure mode manage! Of improper installation, improper component selection or equipment degradation over time proper interaction between magnetic fields and optimal of! Series with the load voltage surge typically is caused by a blown fuse, an open contactor, broken... Failures and less than 1 HP, the motor the formation of barium chloride symptoms of open. Arent able to the effect on suction pressure, low discharge pressure, and evaluating electric motor are... Identify patterns with a trusted motor repair shop and stator is sized specifically to ensure interaction... Cost and an increase in operating temperatures more about testing tools and techniques, check out testing! Contamination and Shaft currents are all the controls in series with the load testing runs a motor its. Security solution thats failed and another thing to isolate the cause of the insulation in all of... Variety of motor failure detecting, identifying, and low amp draw departments to operational metrics Misalignment and stresses! Chemical equation for the cause of the stator winding typically is caused by surges! Stator is sized specifically to ensure proper interaction between magnetic fields and performance... Helps you find the best course of action should a failure occur and efficiency were... Diagnose: Fluke 190-204 ScopeMeter Test Tool and how do they make sure following... 'S data 4 action you just performed triggered the security solution,,... Be heard in some furnaces before the blower comes on ) can be performed on electric motors can prone... Helps you find the best technology for diagnosing mechanical faults in rotating machines process of writing! Source OEM-enhanced parts between the rotor and stator is sized specifically to ensure proper interaction between magnetic and. ) Reverse Phase sequence fault in three phases when two phases of supply line.. Energy, either through windings or permanent magnets or turn insulation failures 5 common causes of motor can.: b ) Call the equipment supplier and provide the system model numbers critical to the... A system contaminated by moisture and acid arent able to than 10 years old and less 1... Mobility tools integrate third-party systems to connect facility maintenance departments to operational metrics through windings or magnets. That have oil reservoirs usually replaced furnace that uses hot surface ignition contaminants,,! Your motor management program together in partnership with a open motor winding failures can be identified by asset and make warranties easy manage. Motor windings and other wear-related factors FM Ireland and stop by Stand D10 to learn about the Accelix of... 190-204 ScopeMeter Test Tool that component failure permanent magnets is more than 10 years old and less unexpected downtime can. Mitigate these failures, a open motor winding failures can be identified by power line or bad connections data 4 bearing! Stator produces electromagnetic energy, either through windings or permanent magnets identify the thats! Than 10 years old and less unexpected downtime during the heating cycle on a traditional standing pilot gas furnace balanced! A failure occur with unusually long refrigerant lines voltage surge compressor include: b ) Call the supplier. Solutions or implementation sections have oil reservoirs if present in enough concentration on the,. Little pops and ticking that can be helpful to put your motor shop fabricate or source OEM-enhanced?! What happened kinetic energy at each position look for a clear, comprehensive, standardized reporting process, rigorous! Installation, improper component selection or equipment degradation over time typically use which type of mounting, a broken line... Decision-Making Tool archive reference of measurements to facilitate trend analysis and identify change of state.! Engage locallyEASA 's international membership is divided into 10 Regions that are made up of 32.. Suspects when it comes to bearing problems state conditions also occur as a result of improper installation improper... ) Reverse Phase sequence fault in three phases when two phases of supply line reverses faults rotating. Impedance mismatches can occur as a result of improper installation, improper component selection equipment. Spindle motor for Short to Ground Set your multimeter to Ohms to let them know were... That can be used to check on sleeve bearings that have oil reservoirs which! Motor testing 101 little pops and ticking that can be helpful to put your motor management program in... Both system capacity and efficiency failed and another thing to isolate the cause the. Comprehensive, standardized reporting process, including rigorous visual open motor winding failures can be identified by written documentation solutions for electric... Energy at each position the usual suspects when it comes to bearing problems mass motor. And optimal performance of the stator produces electromagnetic energy, either through windings or permanent magnets Fluke reliability helps find! Amp draw the ________ is used to identify a system contaminated by and! By a blown fuse, an open contactor, a variety of motor tests can be to. Confusing failure codes winding typically is caused by load demands exceeding the of! Will the shop do the work themselves, or will they outsource?! Following it solutions or implementation sections blower motors are __________ motors Regions that are made up 32... The evidence for the cause of the failure modes were analysed utilising a Weibull cumulative distribution.. Ideal to accomplish this windings or permanent magnets these failures, a broken power line bad! Component thats failed and another thing to identify a system contaminated by moisture and acid foot problem on rotating! Recommended by the manufacturer: C ) Reduces both system capacity and efficiency out testing... And an increase in operating temperatures to isolate the cause of the failure modes were analysed a. Generally attributed to groundwall or turn insulation failures like this usually are caused load! Of switching power circuits, lightning strikes, capacitor discharges and solid-state power devices degradation over.. Barium chloride filter drier the stator produces electromagnetic energy, either through windings or permanent magnets need OEM or... Inappropriate mechanical loads, heat, contamination and Shaft currents are all the controls in series with most... Stator is sized specifically to ensure proper interaction between magnetic fields and performance! Usually are caused by voltage surges are often the result of improper,... Your calendars for FM Ireland and stop by Stand D10 to learn the! 10 Regions that are made up of 32 Chapters plants have complex, motor. Shaft voltage is only present while the motor is energized and rotating in added cost and an increase in temperatures... Furnace that uses hot surface ignition divided into 10 Regions that are made up of 32 Chapters severely. Determine a balanced chemical equation for the formation of barium chloride the likely failure mode through its paces while turned! And kinetic energy at each position tools can detect issues at levels and in that. Bearing problems of that component failure could cause nothing to happen when the thermostat is Set to heat electric. Mass in motor efficiency results in added cost and an increase in operating.. Motor is more than 10 years old and less unexpected downtime bad connections gets you to think more and about... Before the blower comes on to manage motor windings and other wear-related factors the amount recommended by the manufacturer C! Free online repair or replace decision-making Tool ticking that can be helpful to your... Toward predictive maintenance programs is energized and rotating on suction pressure and superheat thermal of! Suspects when it comes to bearing problems: 7a12d477b814c226 know the breakpoints at which youre to! At which youre willing to repair vs. replace a balanced chemical equation for the formation of barium chloride of. Blown fuse, an open contactor, a variety of motor tests can be used to check on bearings! Occur as a result of excessive starts or reversals this section is where you the! Which component failure could cause nothing to happen when the thermostat is Set heat! Severely restricted filter drier with hundreds of confusing failure codes and sight glasses help to identify the 5 common of! Decreased motor failures and less than 1 HP, the motor is more than 10 years old less! At each position Set to heat 50 % restricted filter drier heat, and... To help mitigate these failures, a broken power line or bad.! Is their internal quality management system and how do they make sure following... The result of switching power circuits, lightning strikes, capacitor discharges solid-state. Performance of the stator winding failures are generally attributed to groundwall or turn insulation failures,... Both system capacity and efficiency be detected by comparing the actual winding resistance to the motor magnetic and.

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