open motor winding failures can be identified by
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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. 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. Yet determining the cause is a critical step in protecting your motors. Infrared imagers are the best technology for finding electrical hot spots in switchgear and motor controllers, for the screening process and mechanical assets. Foreign bodies which find their way inside the motor can dent bearing . This guide is intended to help you identify the most common types of bearing failures and know how to prevent them from becoming an unnecessary maintenance expense. 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. When an electric motor fails, theres one question that must be answered. However, electric motors can be prone to any number of issues that lead to motor faults and failures. (Note: almost all misalignment is compound misalignment, but practitioners talk about misalignment as the two separate types because it is easier to correct a misalignment by addressing the angular and parallel components separately.). Next up is advice on troubleshooting, fault testing, motor failure reporting and decision-making, including when to call in a motor shop. Do they follow the ANSI/EASA AR100 best practices? Weve put together a separatepreventive maintenance guideto help you out. A) Fan RPM = Motor RPM Motor Sheave Diameter Fan Sheave Diameter. How static motor testing can support preventative maintenance programmes. The motor and insulation tester assure safe operation, prolongs the life of electrical systems and 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? Here are 3 ways to tell if youre doingpreventive vs predictive maintenance. The correct tension for any belt drive application is: 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 article demonstrates how to detect the 13 most common causes of winding insulation and bearing failure in advance. Soft foot refers to a condition in which the mounting feet of a motor or driven component are not even, or the mounting surface upon which the mounting feet sit is not even. The most common mechanical faults are shaft imbalance, looseness, misalignment, and bearings. Create an archive reference of measurements to facilitate trend analysis and identify change of state conditions. 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. 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. Whats the lead time on a new motor? Ball bearings are used in smaller motors, while the big boys will have roller bearings. De-energized testing runs a motor through its paces while its turned off. quent compressor failure can result within a few hours. 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. Variable frequency drives employ a pulse width modulation (PWM) technique to control the output voltage and frequency to a motor. In the motor if winding is open 33% Stator can induce more current causes winding failure, for creation of vibration rotor winding can fail. A carbon brush probe attachment allows you to measure shaft voltage while a motor is rotating. Weve come up with these. Start reaping the benefits of membership today. Winding Shorted Turn-to-Turn Thermal Stress Failures. Reproduction of these photographs by print or electronic means is prohibited. The essential guide to troubleshooting, repairing and preventing industrial motor problems. Include data and observations. To get a complete picture, evaluate the likely failure modes and match the right maintenance technologies with the most likely failure mode. Simply saying the cause of a motor failure was bearing failure may be true. Winding shorted turn-to-turn Motor starting components can be made up of: Internal centrifugal switches, relays, starting, and running capacitors. 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. Consider the size, age, type and application of your motor. It adducts the humerus. Chances are, you arent the final decision maker on larger operational and capital expenditures. (If youve had small children in your life, youll also have flashbacks.) b) the minimum tension required to keep the belt from slipping at its maximum torque Third, make your motor repair and replace decisions using an industry-accepted decision tree oronline decision toolto standardize and speed up your process. Sales professionals need to keep their skills sharp in order to discover new leads, nurture promising prospects and close more deals. To help mitigate these failures, a variety of motor tests can be performed on electric motors. See more information related to AC and DC Windings in EASA's Resource Library. Does the shop have experience with your motor? a) will draw higher than normal amps The failure rate of the winding in the induction motor was higher than that of the synchronous motor. There are several actions that could trigger this block including submitting a certain word or phrase, a SQL command or malformed data. 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\. 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. EASA's Root Cause Failure Analysis manual covers root cause methodology and the specfic stresses that affect each component of an electric motor. c) moisture And fifth, use your motor shop to help you implement best practices for motor replacement, repair, storage and maintenance at your plant. Often these mechanical faults are related: shaft imbalance, looseness, or misalignment left uncorrected will cause increased forces on the bearings which leads to rapid wear of the bearings. . This problem typically occurs when the insulation in the windings deteriorates. Every robust PM program will includekeyperformance indicatorsso you can measure success and make improvements. Already an expert? Most problems with single-phase motors involve the centrifugal switch, thermal switch, or capacitor(s). When replacing fuses be sure to match which of these ratings? 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 . Most rotors have conductors that carry currents and interact with the magnetic field created by the stator. Re-state what you felt caused the failure. Once acid is identified in However, its important to move toward predictive maintenance programs. 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? 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. In a perfect situation, the sum of the three currents would equal zero. Which of the following formulas can be used to calculate fan speed (RPM)? 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. It treats the underlying condition that created the situation in the first place. 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. Already an expert? 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. 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. The sign to look for is a resistance reading that is different from the manufacturers stated resistance for the winding. When the liquid line is restricted, the supply of refrigerant to the metering device is reduced. Weve come up with these 6 questions to ask deciding whether to repair or replace your electric motor. 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. Does the shop have a significant amount of experience with your motor? B) Call the equipment supplier and provide the system model numbers. Many professionals believe that a flexible coupling eliminates and compensates for misalignment, but a flexible coupling only protects the coupling from misalignment. d) all of these are indicators of correct tension, d) all of these are indicators of correct tension. Uneven mass in motor windings and other wear-related factors. There are two kinds of soft foot: In both cases, soft foot can be caused either by an irregularity in the machine mounting feet, or in the mounting foundation upon which the feet rest. If the circuit to the relay coil is not energizing the coil, the technician should: B) Use the hopscotching technique to find the fault in the circuit, D) Relay coil in series with the run winding and the contacts wired in series with the start winding. Other failures are caused by vibration, physical damage and situations that causes excessive heat. 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. 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. 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. 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. 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