Every electric motor has vents and requires clean and sufficient airflow to ensure peak performance. However, this is dependant on proper maintenance - without which they are likely to break down much quicker. Over heating 4. Over-Current 2. However, any failure would lead to a great loss to the organization. Read on to find out! Instead, you should keep an eye on the motor and wipe down any excess moisture as it builds up. Even if you regularly maintain your electric motor, there’s a possibility that you’ll experience a motor failure at some point. Electric motor is an essential electrical device in the home and industries. As we mentioned previously, overheating is certainly one of the main reasons for motor failure, and the culprit is usually dust and debris. This book was developed to help electric motor technicians and engineers prevent repeated failures because the root cause of failure was never determined. A single-phased winding failure is the result of an open in one phase of the power supply to the motor. There’s no definitive way to predict whether, or when, bearing currents will occur. Ideally, your workplace would be climate-controlled, but we know that’s far from a reality for many. Most of these failures occur due to low resistance. Pumps Plus of Cape Coral is the leading service provider for electrical motors in Southwest Florida. A damaged or burnt out capacitor may … 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. 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. C. Radu, “The most common causes of bearing failure and the importance of bearing lubrication,” RKB Bearings (2010). To minimize the chances of a motor breakdown, it’s important to understand the common causes of motor failure. 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. 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. Motor capacitors store electrical energy for the motor to use. Martin McGuffie explains three common causes of electric motor failure: weakened insulation, contamination and lack of maintenance. If a motor is started off at a bad current value, it starts operating in a much warmer condition than the design temperature. Want to troubleshoot, repair and prevent electric motor failure at your plant? These winding failures fall into four major categories related to what causes them: thermal stress, mechanical stress, electrical stress, and environmental stress. If you’d like to learn the typical causes of electric motor failure, we’ve got you covered. Depending on how dusty your workplace is, it may be best to clean your motor after each day. By automating many processes, companies can allow the machinery to handle repetitive work and put the actual workers to better use elsewhere. The higher the capacitance of the capacitor the more energy it can store. To avoid an over-current, there are some devices that need to be installed that can prevent it from happening. electric motors. 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. What is the Biggest USA Naval Aircraft Carrier Now? B. Mechanical failures and over-current failures are also very common. Electric motors are essential for making sure that plants are running smoothly and effectively. Usually in large organizations, a motor maintenance program is carried out in which the causes of motor failures are identified and some necessary steps are taken to avoid them or lower their impact. When not cared for properly, an electric motor lasts 20,000 hours at most. 6. As a family-owned business that started as a motor repair shop, Moley Magnetics has you covered. Shielding devices are available which are used for this purpose. Motors today have a long service life and require a minimum level of maintenance to make sure that they perform efficiently. 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 … It can damage the motor by blocking the cooling fan which causes its temperature to raise. 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. 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. What causes broken bars though, and how can you fix them? Moisture: Moisture also affects the performance of electric motors. A damaged or burnt out capacitor may … 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- HVAC: Heating, Ventilation & Air-Conditioning, Commercial Applications & Electrical Projects, Commercial Energy Usage: Learn about Emission Levels of Commercial Buildings, Time to Upgrade Your HVAC? One of the most common, of course, is natural degradation. Back. As you already know, electric motor is used everywhere in industry and in term of technology – it’s already pretty complex, sometimes making it a challenge to keep it running at peak performance. 5 Causes of Motor Failure and How to Prevent Them. Five Most Common Reasons for Failure in Electric Pump Motors. Motors are employed across the industrial sector. And when the electric motor fails, it causes significant downtime and inconvenience for manufacturers. What causes electric motors to fail? Motors form the backbone of almost all major industrial operations, irrespective of the industry chosen. Whenever a problem occurs, it should be corrected immediately to avoid further loss. This causes the rate at which heat can be conducted to reduce at an alarming rate. Failure surveys. 3. Everything breaks down eventually, especially when used in machines. The alignment of the motor should be checked to eliminate this issue. Overheating is another issue that can cause a motor failure. The life of the insulation in a standard electric motor is based on the temperature at which the motor operates. Motor Shaft Materials For most motor applications, hot rolled carbon steel is a good choice. Motor Shaft Materials For most motor applications, hot rolled carbon steel is a good choice. Most of these failures occur due to low resistance. Most failure survey data for electric motors is influenced by the particular industry, the geographic location, and the combination of the motors in use. Many facilities and job sites that use motors have lots of dust and debris. 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. 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. 4. fying the root cause of bearing and shaft failures in electric motors. It is important that the insulation performance is monitored at regular intervals. Inspect them regularly and ensure that maintenance activities are performed periodically, regardless of whether it is a new or used electric motor. or corrosion. 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. These motors are not put at risk by a phase failure. Motors in star connection. However, the result is usually the same: pitting damage to the rolling elements and raceways, rapid degradation of the lubricant and premature bearing failure. July 18, 2018. 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. Foreign bodies which find their way inside the motor can dent bearing raceways and balls, leading to high levels of vibration and wear. 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. Thermal Stress Failures. Corrosion of parts can also cause the motor to vibrate. So naturally, a motor’s airflow pulls that dust and debris towards the motor’s vents, and eventually inside the motor. Low Resistance: Most motor failures occur due to low insulation resistance. It can damage the motor by blocking the cooling fan which causes its temperature to raise. Dirt: Dirt is one of the major sources that cause damage to the electric motors. Barden Precision Bearings, “Bearing Failure: Causes & … Determining Causes for Electric Motor Failure written by: Umair Mirza • edited by: Lamar Stonecypher • updated: 12/27/2013 It is estimated that 92% of the electric motor failures occur at the start up. Alternatively, if you’re sure that you have adequate power and your motor still failed, a common reason for failure is power surges. While it may seem obvious, the environment surrounding your electric motor can have a significant impact. 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. 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]. 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. Failure surveys. A phase failure is an interruption of a single conductor. All Rights Reserved. There can be numerous reasons that may cause a motor to fail. Electric motors have arguably been the sole reason for increased efficiency and productivity in industries like manufacturing, automotive, construction, and so many more. If the capacitor has failed the symptom is that the motor won't start. Small to medium sized motors are mostly stator critical – this means that only the stator can be damaged. Every electric motor has a design temperature. Along with the photo is a brief explanation of the cause of the problem. A lack of useful facts needed to determine the root cause. Keep work areas, tools and fixtures as clean as possible to help eliminate the chance of … Electric motors top the industrial landscape as the most widely deployed asset driving processes and productivity. Overheating causes the motor winding insulation to deteriorate quickly. 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. Here, Martin McGuffie, service manager of It can also affect the insulating value of the winding insulation if it settles on the motor windings. The frequent use of variable frequency drives (VFDs) can result in detrimental effects to electric motors because of the condition of power in manufacturing facilities. Martin McGuffie explains three common causes of electric motor failure: weakened insulation, contamination and lack of maintenance. Want to troubleshoot, repair and prevent electric motor failure at your plant? Together, these tests will paint a picture of motor health and provi… Normally electrical motor insulation can be effected by many factors.Below are several common factors that effected the insulation failures. It greatly contributes in the corrosion of the motor shafts, bearings and rotors. 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. Electrical failures, including single-phased winding failures (wye- or delta-connected) caused by an opening from a blown fuse, open contactor, bro… Contamination from dust, dirt and chemicals is one of the leading causes of motor failure. 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. A bad motor capacitor may cause starting problems or could shut off the motor while running. Causes of Broken Bars. 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. Electric motors are an essential part of an industry and numerous applications and systems depend on them. 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. Possible solution: Preventing contamination is relatively easy. In the past few years with the wide use of PWM inverter drives, motor bear … 2. If they are well-maintained, they will have a long life. The Electro-Mechanical Authority (EASA) cites many causesof electric motor winding failures including: 1. In fact, there are some common reasons for electric motor failures. Moisture and humidity are a lot like dust and debris, because as the moisture builds up, your chance of overheating increases. Posted on May 15, 2019 by Premier Automation. Modern electric motors may be more efficient and reliable than their ancestors, but they can still fail sometimes. However, any failure would lead to a great loss to the organization. The cause is, for example, blown fuse. In the initial stages of motor installation, the insulation resistance is observed to be more than one thousand megaohms. Alternatively, the vibration could be a sign of worn out bearings. It is very important that the motors should be matched with their ideal current values. Abstract: A broad comparative study of the causes of electric motor failure is difficult to accomplish. There are many causes for broken bars. 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- Welcome to our new and improved Moley Magnetics website! Electric motor starting & run capacitor troubleshooting FAQs Questions & Answers about Electric Motor Start-Boost or Run Capacitors Capacitors are electric devices that get an electric motor running at start-up or that help keep a motor running once it has started. 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. B. Both indoor and outdoor workplaces could be hot and humid, which is a recipe for motor failures. While electric motors have undoubtedly made many jobs easier and streamlined a multitude of processes, these motors also require maintenance. As shown in Figure 1, the currents in the motor windings, during disturbed and undisturbed operation at the failure of a single conductor, equal the currents in the other two. Modern electric motors may be more efficient and reliable than their ancestors, but they can still fail sometimes. Due to the increasing current, a higher power loss occurs in both live windings. Over Heating Excessive heat in motors can cause a number of performance problems. The extent of the damage depends on the amount of energy and its duration. If they are well-maintained, they will have a long life. 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; 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. 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. All electric motors have their predetermined life span, typically ranging from 30,000 to 40,000 hours. A few of the symptoms of overcurrent in a motor are shorts, blown fuses and unintended switching on and off of the motor. electric motors. There are six main causes of electric motor failures: These causes are briefly explained below: 1. However, this is dependant on proper maintenance – without which they are likely to break down much quicker. Top five causes of electric motor failure … October 23, 2015 By Mike Hurlbatt. winding failure and possible causes,electric motor rewinds,illustrated guide to winding failures The photos below are typical winding failures in three phase stators. This issue is considered to be the most difficult one to tackle. One of the common reasons an electric motor fails is overheating. 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. All electric motors have their predetermined life span, typically ranging from 30,000 to 40,000 hours. Professional Electric Motor Repair Services, Essential Equipment You Need for a Scrap Yard. Here's What You Need to Know, 4 Most Common HVAC Issues & How to Fix Them, Fluid Mechanics & How it Relates to Mechanical Engineering, Hobbyist & DIY Electronic Devices & Circuits, Naval Architecture & Ship Design for Marine Engineers. Modern electric motors may be more efficient and reliable than their ancestors, but they can still fail sometimes. Electrical failures are winding failures caused by an open contactor, bad connection, blown fuse, excessive heat, electrical overload, or broken power lines. Trouble is, the causes of electrical motor failure are nuanced and complex, since various issues can contribute to a problem that […] 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 failure can cause downtime, an inconvenience for all manufacturers. If you use too much or too little, your motor could overheat and possibly result in internal damage to the motor. 5. Though, many facilities fail to keep up with regular maintenance such as cleaning their equipment. 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. Overcurrent protection is one of the essential elements of a proper electrical installation. Electric erosion or arcing, can happen when a current passes from one ring to the other through the rolling elements. in Cape Coral, Florida. 1) Contamination : A chemical reaction or deposit on the windings that cause deterioration of the varnish insulation. SKF, “The 5 most common causes of bearing failures in electric motors and what to do about them,” (February 2017). If you’re unsure whether you have adequate power or not, we’d encourage you to hire a professional industrial electrician. “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. 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