A single-phased winding failure is the result of an open in one phase of the power supply to the motor. Foreign bodies which find their way inside the motor can dent bearing raceways and balls, leading to high levels of vibration and wear. Overcurrent protection is one of the essential elements of a proper electrical installation. This book was developed to help electric motor technicians and engineers prevent repeated failures because the root cause of failure was never determined. Read on to find out! Motors form the backbone of almost all major industrial operations, irrespective of the industry chosen. Motor manufacturers are involved in failure studies, as such, but only as far as is appropriate to satisfy warranty requirements. Winding failures are some of the most common electric motor repair causes. June 12, 2017 By Danielle Collins Leave a Comment Variable frequency drives convert AC input voltage to DC, and then back to pulse-width-modulated AC voltage with variable frequency. Electric motor is an essential electrical device in the home and industries. A lack of experience. Over heating occurs due to a number of factors. Motor failure can cause downtime, an inconvenience for all manufacturers. By Thomas H. Bishop, P.E., Electrical Apparatus Services Association (EASA) If you want to make a plant manager’s day, just say: “Production’s down because a motor failed.” Fortunately, such situations can usually be overcome with some relatively simple techniques and straightforward solutions … There are six main causes of electric motor failures: 1. Common Causes of Electrical Motor Failure. Corrosion of parts can also cause the motor to vibrate. We’d encourage you to keep the motor under a tent or another source of shade on the job site to reduce the chances of overheating. A bad motor capacitor may cause starting problems or could shut off the motor while running. When these gadgets fail, work often grinds to a halt till they’re back up and running, and the reasons for electrical motor failure can range from the commonplace to the bizarre. The extent of the damage depends on the amount of energy and its duration. One of the common reasons an electric motor fails is overheating. Alternatively, if you’re sure that you have adequate power and your motor still failed, a common reason for failure is power surges. For example, if a 100 hp motor has an unbalance factor of 3 percent, the motor should be derated to 0.88 or 88 percent of capacity, 88 hp. Temperature plays a major role in motor failure. It’s important to remember that the causes of motor and drive issues are not confined to a single domain of expertise–both mechanical and electrical issues can lead to motor failure–and being armed with the right knowledge can mean the difference between costly downtime and improved asset uptime. C. Radu, “The most common causes of bearing failure and the importance of bearing lubrication,” RKB Bearings (2010). However, this life cycle is dependant on if they receive the proper care. When higher loads are present, an alloyed steel such as chromium–molybenum (Cr–Mo) is frequently used, and for ... mental knowledge of motor shaft failure causes and visual in- In general, in large organizations, an engine maintenance program is carried out in which the causes of the engine failures are identified and the necessary measures are taken to avoid them or reduce their impact. This can lead to an insulation failure also. Overloading is the leading cause of electric motor failure. This issue is considered to be the most difficult one to tackle. Many facilities and job sites that use motors have lots of dust and debris. As the technology that goes into motors becomes more and more complicated, it is vital for engineers and technicians to know about what causes electric motor failure. There are various common causes of motor failure, among which 45% are bearing failure, 35% are stator winding failure, 10% are rotor failure, and another 10% are other damages [4]. There can be numerous reasons that may cause a motor to fail. After some time, the insulation performance starts to degrade at an alarming level because the resistance starts to decay gradually. However, this is dependant on proper maintenance - without which they are likely to break down much quicker. Martin McGuffie explains three common causes of electric motor failure: weakened insulation, contamination and lack of maintenance. However, this is dependant on proper maintenance – without which they are likely to break down much quicker. Sometimes your motor could overheat because you’re overloading the circuit. If you’re unsure whether you have adequate power or not, we’d encourage you to hire a professional industrial electrician. Electric motors are essential to numerous plants operations, no matter the industry, which is why understanding their 50 failure modes can help you develop a better maintenance program in your plant. To do so, understanding the underlying causes of motor failures is critical to determine the best course of action should a failure occur. Luckily, failure doesn’t mean you need to replace your motor. Modern electric motors may be more efficient and reliable than their ancestors, but they can still fail sometimes. The following greases can be used for high speed cast iron motors but not mixed with lithium complex greases: - Klüber Klüber Quiet BQH 72-102 (polyurea base) - Lubcon Turmogrease PU703 (polyurea base) If other lubricants are used; To truly understand, identify, diagnose and ultimately prevent the common causes of electric motor failure, each cause needs to be explored in depth. There are six main causes of electric motor failures: Over-Current; Low Resistance; Over heating; Dirt; Moisture; Vibration; These causes are briefly explained below: 1. The causes of electrical motor insulation failures 17/06/2012 by Lemau Leave a Comment Basically electrical motor have a phase to phase winding coil around armature to created a magnetic field.To avoid shortage between phase to phase winding,the insulation systems needed. Inspect them regularly and ensure that maintenance activities are performed periodically, regardless of whether it is a new or used electric motor. To minimize the chances of a motor breakdown, it’s important to understand the common causes of motor failure. All electric motors have their predetermined life span, typically ranging from 30,000 to 40,000 hours. By having the motor outside in the sun, it’s only a matter of time before your motor overheats, especially if it’s not clean. Small to medium sized motors are mostly stator critical – this means that only the stator can be damaged. If you're still having problems with your motor capacitor, give us a call now at 239-574-4499 or visit our shop at 958 Country Club Blvd. It's common to use the results of failure surveys to diagnose the cause of a specific motor failure, but it can be a costly mistake. fying the root cause of bearing and shaft failures in electric motors. The life of the insulation in a standard electric motor is based on the temperature at which the motor operates. Mechanical failures and over-current failures are also very common. Top five causes of electric motor failure … Moisture: Moisture also affects the performance of electric motors. So naturally, a motor’s airflow pulls that dust and debris towards the motor’s vents, and eventually inside the motor. Contamination from dust, dirt and chemicals is one of the leading causes of motor failure. Installation issues: Sometimes when a motor displays problem symptoms, the issue is down to faulty installation, which can cause problems like soft foot, pipe stain and shaft voltage. You may be on top of your lubrication schedule with your motor, but you may have forgotten a basic maintenance requirement––keeping the motor clean. Causes of insulation failures. This causes the rate at which heat can be conducted to reduce at an alarming rate. Overheating also occurs when an electric motor is forced to operate in a high temperature environment. Although you should always take care of an electric motor and perform basic maintenance, you should never take your motor apart in an attempt to “find the problem.” Instead, bring or ship your motor to a professional and reliable repair service. Motor capacitors store electrical energy for the motor to use. Though the vibration may not seem like a big issue, you should never let a motor vibrate for an extended amount of time, as it can cause permanent damage. Motor failure can cause downtime, an inconvenience for all manufacturers. Every electric motor has a design temperature. Common Causes of Electric Motor Failure Operational overloads – which can account for up to 1/3 rd of all motor failures, and occurs when your motor is under an excessive load that leads to electrical overloads, insufficient torque, and/or eventual overheating that can wear down components like bearings, motor windings, and more. Before installing a new electric motor, you must ensure you have adequate power in the area, otherwise your motor will fail and potentially cause outages. Overheating causes the motor winding insulation to deteriorate quickly. When not cared for properly, an electric motor lasts 20,000 hours at most. By automating many processes, companies can allow the machinery to handle repetitive work and put the actual workers to better use elsewhere. By some accounts, electrical damage (damage caused by electric discharge machining) is the most common cause of failure for AC motors driven by VFDs. Alternatively, the vibration could be a sign of worn out bearings. Unfavorable operating conditions — whether electrical, mechanical or environmental — can dramatically shorten the life of an electric motor. However, with all the typical causes of electric motor failure discussed above, many failures are easily reversible and preventable. Our family will be happy to serve you. In the past few years with the wide use of PWM inverter drives, motor bear … If the capacitor has failed the symptom is that the motor won't start. Pumps Plus of Cape Coral is the leading service provider for electrical motors in Southwest Florida. Electric erosion or arcing, can happen when a current passes from one ring to the other through the rolling elements. Typically, the vibration is a result of the motor being uneven or incorrectly positioned. Many professionals believe that a flexible coupling eliminates and compensates for misalignment, but a flex- Protecting motor bearings and windings is the first step in preventing motor failures. Identifying hidden problems in electric motors that can be repaired or replaced can optimize a motor’s efficiency and performance and save time, money and headaches. Welcome to our new and improved Moley Magnetics website! Dirt: Dirt is one of the major sources that cause damage to the electric motors. It’s VERY important to remember that the causes of motor and drive issues are not confined to a single domain of expertise – both mechanical and electrical issues can lead to motor failure – and being armed with the right knowledge c… These winding failures fall into four major categories related to what causes them: thermal stress, mechanical stress, electrical stress, and environmental stress. Many facilities and job sites that use motors have lots of dust and debris. Back. Electric motors are an essential part of an industry and numerous applications and systems depend on them. Over heating 4. The higher the capacitance of the capacitor the more energy it can store. Electric motors top the industrial landscape as the most widely deployed asset driving processes and productivity. 5 Fluke Corporation 13 common causes of motor failure Misalignment occurs when the motor drive shaft is not in correct alignment with the load, or the component that couples the motor to the load is misaligned. Unless it is the hermetically sealed motor in a submersible pump, an electric motor is quite efficient at drawing in dust particles from the air as it runs. As a family-owned business that started as a motor repair shop, Moley Magnetics has you covered. Once the particles reach the inside of the motor, they can cause a lot of damage. Not to mention, moisture and electrical items are never a good combination. The higher the capacitance of the capacitor the more energy it can store. Motor Shaft Materials For most motor applications, hot rolled carbon steel is a good choice. But when noise occurs, the damage has usually become substantial enough that failure is imminent. When electric motor fails – you can do few things, but before motor fails – you can do many many things to suppress eventual failure or heavy damage. It can also block the cooling fan, limiting the motor’s ability to regulate its temperature, and increasing the likelihood of overheating. Motors today have a long service life and require a minimum level of maintenance to make sure that they perform efficiently. If they are well-maintained, they will have a long life. One of the most common, of course, is natural degradation. electric motors. By Thomas H. Bishop, P.E., Electrical Apparatus Services Association (EASA) If you want to make a plant manager’s day, just say: “Production’s down because a motor failed.” Fortunately, such situations can usually be overcome with some relatively simple techniques and straightforward solutions … If you’re ever in need of a motor repair, a new motor, shears, magnets, and more, contact us today. For every ten centigrade rise in temperature, the insulation life is cut in half. Most of these failures occur due to low resistance. What causes broken bars though, and how can you fix them? Barden Precision Bearings, “Bearing Failure: Causes & … Our family has extensive industry experience to the point where we can take your motor apart and get it back up and running in no time. What is the Biggest USA Naval Aircraft Carrier Now? Motors in star connection. All electric motors have their predetermined life span, typically ranging from 30,000 to 40,000 hours. Electrical failures, including single-phased winding failures (wye- or delta-connected) caused by an opening from a blown fuse, open contactor, bro… One of the common reasons an electric motor fails is overheating. If you’d like to learn the typical causes of electric motor failure, we’ve got you covered. Low Resistance 3. However, the result is usually the same: pitting damage to the rolling elements and raceways, rapid degradation of the lubricant and premature bearing failure. Electric Motor failure occurs due to overheating, phase unbalance, voltage unbalance, single-phasing, surge voltages, poor ventilation, lack of lubrication, overloads, over cycling, excessive moisture, improper belt tension, misalignment and vibration, loose connections, pests, etc. Want to troubleshoot, repair and prevent electric motor failure at your plant? It is important that the insulation performance is monitored at regular intervals. The Bardenpho Process of Wastewater Treatment leads to better Quality Treated Water. Over-Current (Electrical Overload): In different operating conditions, electrical devices will sometimes start to draw more current than their overall capacity. Static testing, which is performed when a motor is off-line, can determine the condition of a motor’s insulation and circuit, while dynamic motor analysis, which is performed while a motor is operating, can pinpoint issues related to power quality, motor performance and load. The open is usually caused by a blown fuse, an open contactor, a broken power line or bad connections. If you use too much or too little, your motor could overheat and possibly result in internal damage to the motor. Dirt: Dirt is one of the major sources that cause damage to the electric motors. Proper steps should be taken to prevent the motors from dirt. Common Causes of Electric Motor Failures. Leading standardization organizations have concluded that 30 percent of motor failures are attributed to insulation failure and 60 percent of these are caused by overheating. The lifespan of an electric motor is predetermined from the time of their creation. In fact, there are some common reasons for electric motor failures. A damaged or burnt out capacitor may … Now, we understand that shade and tents aren’t always available on job sites, and that’s okay, since it’s unlikely that the sun will permanently damage your motor. Winding insulation breakdown and bearing wear are the two most common causes of motor failure, but those conditions arise for many different reasons. or corrosion. B. If you notice that your motor is vibrating excessively, that should be a red flag that something is wrong and that you may need a repair. Protecting motor bearings and windings is the first step in preventing motor failures. Everything breaks down eventually, especially when used in machines. If a motor is started off at a bad current value, it starts operating in a much warmer condition than the design temperature. Due to the increasing current, a higher power loss occurs in both live windings. Continue reading to learn more. It has been concluded that more than 55% of the insulating failures are caused by over heating. However, we would suggest that you use the motor sparingly and allow it enough time to cool down, otherwise you could overheat the motor, and consistent overheating can lead to long-term damage. All Rights Reserved. The Electro-Mechanical Authority (EASA) cites many causesof electric motor winding failures including: 1. Normally electrical motor insulation can be effected by many factors.Below are several common factors that effected the insulation failures. If you’re certain your motor is properly aligned and it’s still vibrating, you should reach out to Moley Magnetics sooner rather than later for servicing. Moisture and humidity are a lot like dust and debris, because as the moisture builds up, your chance of overheating increases. 3. “Low or high voltage is actually not the cause of electric motor failure as frequently as one would suspect,” says Prince, “unless the voltage change is greater than 10%.” Motors do not give satisfactory service if the voltage consistently varies by more than +/- 10% from the nameplate rating. For more information on common causes of electric motor failure from the experts at Fixall Electric Motor Service, please contact us here or call us directly at 616.454.6863. This unpredictable event will happen very suddenly and will greatly impact the motor. As a leading supplier and servicer in the industry, Moley Magnetics is a respected and well-recognized company that values high-quality products and services. Motors need to be inspected regularly, and other maintenance activities need to be performed to ensure efficient operation. As we mentioned previously, overheating is certainly one of the main reasons for motor failure, and the culprit is usually dust and debris. Most failure survey data for electric motors is influenced by the particular industry, the geographic location, and the combination of the motors in use. Trouble is, the causes of electrical motor failure are nuanced and complex, since various issues can contribute to a problem that […] Though, many facilities fail to keep up with regular maintenance such as cleaning their equipment. While electric motors have undoubtedly made many jobs easier and streamlined a multitude of processes, these motors also require maintenance. While we’ve expanded our business into industrial magnets, alligator shears, pumps, and more, we haven’t lost touch with our roots. Keep work areas, tools and fixtures as clean as possible to help eliminate the chance of … Stressful mechanical, environmental, and electrical operating conditions can all cause electric motor failure. Insulation breakdown, cycling and flexing, along with AC drive stress, round out the possible failure modes for this category. A bad motor capacitor may cause starting problems or could shut off the motor while running. The motor inventory should be kept dry all the time. A 3% voltage unbalance causes an 18% temperature rise in the motor and a current increase of six to ten t… Most electric motors last 30,000- 40,000 hours. It’s important to remember that the causes of motor and drive issues are not confined to a single domain of expertise–both mechanical and electrical issues can lead to motor failure–and being armed with the right knowledge can mean the difference between costly downtime and improved asset uptime. So naturally, a motor’s airflow pulls that dust and debris towards the motor’s vents, and eventually inside the motor. It's common to use the results of failure surveys to diagnose the cause of a specific motor failure, but it can be a costly mistake. However, any failure would lead to a great loss to the organization. When higher loads are present, an alloyed steel such as chromium–molybenum (Cr–Mo) is frequently used, and for ... mental knowledge of motor shaft failure causes and visual in- Martin McGuffie explains three common causes of electric motor failure: weakened insulation, contamination and lack of maintenance. Copyright © 2020 Bright Hub PM. Motor windings account for about 32% of all AC electric motor repairs. What causes electric motors to fail? For instance, if you’re working outside at a construction site, you’re not only going to have an issue with debris but with the temperature itself. Thermal Stress Failures. Phase failure. Failure surveys. Posted on May 15, 2019 by Premier Automation. A phase failure is an interruption of a single conductor. Instead, you should keep an eye on the motor and wipe down any excess moisture as it builds up. Shielding devices are available which are used for this purpose. Failure to understand the total cost. The area where electric motors are operating must have a proper cooling system and a ventilation system should be there in case the cooling system stops working. The high speed grease is also used in motor types M2CA, M2FA, M2CG and M2FG, frame sizes 355 to 400 2-pole machines. Get tips for report writing, root cause analysis, motor management and more! Ideally, your workplace would be climate-controlled, but we know that’s far from a reality for many. Introduction However, overheating can occur for a few different reasons. Both indoor and outdoor workplaces could be hot and humid, which is a recipe for motor failures. Electrical failures are winding failures caused by an open contactor, bad connection, blown fuse, excessive heat, electrical overload, or broken power lines. July 18, 2018. While it may seem obvious, the environment surrounding your electric motor can have a significant impact. Ensure that your electric motor is properly cared for and it will last for years to come, providing you support, just as you do it. Get tips for report writing, root cause analysis, motor management and more! Electric motors are considered to be a very technical piece of equipment and if your machines or tools contain an Top Three Common Causes Of Electric Motor Failure - Get Ignite TRENDING A few of the symptoms of overcurrent in a motor are shorts, blown fuses and unintended switching on and off of the motor. As an example, if a motor that would normally last 20 years in regular service is running 40 C above rated temperature, the motor would have a life of about 1 year. 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