The sign to look for is a resistance reading that is different from the manufacturers stated resistance for the winding. Energized testing takes place while the equipment is under a simulated load to reveal problems that occur during operation. Special rates good through June 1. Once acid is identified in 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. In either case, any soft foot condition must be discovered and remedied before proper shaft alignment can be achieved. Yet determining the cause is a critical step in protecting your motors. If the failure was catastrophic, repair may not be a good idea. Consider the size, age, type and application of your motor. What is the most likely cause of flames that are lifting off the burner? Skip to the next section on. To get a complete picture, evaluate the likely failure modes and match the right maintenance technologies with the most likely failure mode. Extent of failure. And so on. When is the gas valve energized on an induced-draft furnace that uses hot surface ignition? a) contamination Even if theres still some life left in the motor, youll want to ensure you have a good stator before rewinding. 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. To keep operations running smoothly, implementing preventive maintenance programs leads to a predictive and prescriptive maintenance future. Common causes of winding failure include high temperature, too many starts, contamination, too much current, excessive voltage and physical damage. A winding failurewhich is often caused by a breakdown of the windings insulationwill cause a short in the motor. In other words, there is a heavy spot somewhere on the rotor. But if youre honest, how much of your time is spent firefighting instead of focusing on your to-do list? These tools can assess electronic harmonics, distortion, and load studies. You can identify dead shorts, loose connections and open circuits in coiled windings using a digital multimeter. Simply stated, harmonics are any unwanted additional source of high frequency AC voltages or currents supplying energy to the motor windings. Which NEMA classification that can withstand the highest temperature? How many years of experience do they have? Not so fast. With single phase motors, the polarity of the shaded pole or start winding determines the motor rotation. 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. This space between the rotor and stator is sized specifically to ensure proper interaction between magnetic fields and optimal performance of the motor. quent compressor failure can result within a few hours. c. It abducts the arm. This can lead to bearing destruction within a few months of motor operation. A failed bearing has increased drag, emits more heat, and has lower efficiency because of a mechanical, lubrication, or wear problem. Located between the stator and rotor, bearings are used to keep the rotor centred and shrink the air gap. Check the bearings to make sure they can spin freely. Start by completely disconnecting the spindle motor from all power sources. When the liquid line is restricted, the supply of refrigerant to the metering device is reduced. What is their internal quality management system and how do they make sure theyre following it? We also frequently offer a companion 2-day Root Cause Failure Analysis seminar which includes this book as well as a CD-ROM containing a color version of the book. In addition, misalignment may feed vibration into both the load and the motor drive shaft. Nearly half (48 percent) of all motor failures are due to electrical issues, according to a survey by the Electric Power Research Institute (EPRI). Will the shop do the work themselves, or will they outsource it? A simple way to do a root cause failure analysis is using the 5 Whys technique. Fluke Accelix presents at FM Ireland 2018! What is a common symptom of a severely restricted filter drier? Instrument to measure and diagnose: Fluke 810 Vibration Tester. Impact: Accelerated wear on rotating components resulting in bearing failure. Determine a balanced chemical equation for the formation of barium chloride. 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. 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. A root cause failure analysis can be relatively quick and informal. From its position in the periodic table, determine which atom in each pair is more electronegative: (a) N or P (b) N or Ge (c) S or F (d) Cl or S (e) H or C (f) Se or P (g) C or Si. 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. The resistance of ________ can accurately be predicted using Ohm's law. 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. Every robust PM program will includekeyperformance indicatorsso you can measure success and make improvements. 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). 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. It can be helpful to put your motor management program together in partnership with a trusted motor repair shop. Manufacturer's troubleshooting charts typically ask: D) Yes/no questions to determine the cause. 4. Which of the following formulas can be used to calculate fan speed (RPM)? A single-phased winding failure is the result of an open in one phase of the power supply to the motor. An open door switch on a gas furnace will cause: A) A complete system shutdown-no system operation at all. Infrared sensors can seamlessly integrate with a software platform that gathers data from many other sensor types. This is the logical outcome, given what youve written in the rest of the report. The expected temperature drop through a direct expansion evaporator coil: D) Can be determined with a chart supplied by the coil manufacturer. Get thebearing failure checklist. Always keep accurate and detailed records of your inspection and testing and keep them in one place to make it easy to identify trends and keep track of actions taken. When charging a capillary tube system that holds 100 oz., the charge must be: B) Within 5 percent, between 95 and 105 oz. 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. 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. Some plants prefer to perform their own motor repairs. 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. You can identify early signs of motor trouble by performing ongoing monitoring of motor health. In this case, different is better. Design is critical to the repair-replace decision. The primary symptoms that accompany a motor overload are excessive current draw, insufficient torque and overheating. 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. Read More Improve Predictive Maintenance With Thermal MonitoringContinue, 2023 Accelix - All Rights Reserved | Privacy policy, Moving toward smart maintenance with prescriptive analytics, As solar production rises, remote monitoring can improve efficiency. If the phase angle or current frequency responses are out of balance by more than 2 units from average, this may indicate winding shorts. . Why. Bearing failure is an expensive problem both in terms of motor repair and downtime, so helping to prevent this by measuring shaft voltage and bearing current is an important diagnostic step. 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: Most indoor blower motors are __________ motors. The motor and insulation tester assure safe operation, prolongs the life of electrical systems and motors. That doesnt mean humans are off the hook, however. EASA's Root Cause Failure Analysis manual covers root cause methodology and the specfic stresses that affect each component of an electric motor. EASA's new streaming sales videos provide relevant and insightful training. 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