The trouble free operation of induction motors over the greater part of their se rvice life, which in many

instances, exceeds that of driven equipment, requires little more than regular and routine maintenance chores. Regular cleaning, corre ct lubrication, and proper maintenance, is all that is required to ensure a cons istently high level of performance from a motor, that is correctly selected and properly installed. In essence, the useful service life of a motor is largely a function of the quality of maintenance. Maintenance is all the more important, i n the context of the present-day motors as they are precisely designed to exact ratings and optimized parameters. Hence, any lapse in the proper maintenance of the motors is likely to affect the performance. It has been established through field experience that the majority of the failur es occur because of the following: ? Insulation failures ? Rotor-bar failures ? Mechanical problems. The maintenance program for a motor is given as follows: 1. Periodic inspection of motor. Accurate shaft alignment. For directly coupled motors, shaft alignment between load and motor shaft should be proper. In case o f belt-type system, check for belt condition, belt tension. 2. Check motor heating. If motor heats up quickly, check and clean air filters. Therefore, the airflow will be adequate. 3. Keep motor clean and free from dirt and oil. 4. Check for dampness around the motor or inside the motor. This can reduce insu lation strength of motor winding. As far as possible, keep motor dry internally as well as externally. Also, run motor for few hours if not in use for a long ti me so that moisture dries. Troubleshooting AC motors and starters 107 5. Check bearing condition on a regular basis. Bearing should be lubricated with prescribed lubricant. At the same time, keep in mind that lubrication should be always done in proper quantity. Excess as well as lesser quantity can do harm. 6. Check for any abnormal noise or excess vibrations from motor or coupling. Do vibration analysis if necessary. If the above guidelines are followed, the motor will remain problem free. Motors driven by variable speed drives have specific requirements for correct pe rformance such as special cooling, bearing insulation, use of terminal filters t o absorb high voltage pulses, etc. In the case of retrofitted drives, the manufa cturer needs to be consulted and any additional measures recommended need to be incorporated to avoid failures of motor. Introduction Electric motors are an essential part of our daily life as many systems, applica tions, and services depend on them. Motors today have a long service life and re quire a minimum level of maintenance to make sure that they perform efficiently.

In large buildings, motors have to be maintained on a regular basis because the y need to be in operation all the time; one small problem could cause a great lo ss to the organization. Usually in large organizations, a motor maintenance program is carried out in wh ich the causes of motor failures are identified and some necessary steps are tak en to avoid them or lower their impact. Motors need to be inspected regularly, a nd other maintenance activities need to be performed to ensure efficient operati on. Whenever a problem occurs, it should be corrected immediately to avoid furth er loss. Common Causes of Electric Motor Failures 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. Over-Current (Electrical Overload): In different operating conditions, electr ical devices will sometimes start to draw more current than their overall capaci ty. This unpredictable event will happen very suddenly and will greatly impact t he motor. To avoid an over-current, there are some devices that need to be insta lled that can prevent it from happening. These devices are usually wired in the circuits and will automatically shut down the extra amount of current flowing in the circuit. 2. Low Resistance: Most motor failures occur due to low insulation resistance. T his issue is considered to be the most difficult one to tackle. In the initial s tages of motor installation, the insulation resistance is observed to be more th an one thousand megaohms. After some time, the insulation performance starts to degrade at an alarming level because the resistance starts to decay gradually. A fter a lot of research, a solution has been found which can prevent low resistan ce failures. There are automatic devices that test insulation resistance from ti me to time and safeguard rotating equipment is installed that prevents such fail ures. It is important that the insulation performance is monitored at regular in tervals. 3. Over Heating Excessive heat in motors can cause a number of performance probl ems. Overheating causes the motor winding insulation to deteriorate quickly. For every ten centigrade rise in temperature, the insulation life is cut in half. I t has been concluded that more than 55% of the insulating failures are caused by over heating. Over heating occurs due to a number of factors. Every electric motor has a desig n temperature. If a motor is started off at a bad current value, it starts opera ting in a much warmer condition than the design temperature. It is very importan t that the motors should be matched with their ideal current values. Overheating also occurs when an electric motor is forced to operate in a high te mperature environment. This causes the rate at which heat can be conducted to re duce at an alarming rate. The area where electric motors are operating must have a proper cooling system and a ventilation system should be there in case the co oling system stops working. 4. Dirt: Dirt is one of the major sources that cause damage to the electric moto rs. It can damage the motor by blocking the cooling fan which causes its tempera

ture to raise. It can also affect the insulating value of the winding insulation if it settles on the motor windings. Proper steps should be taken to prevent th e motors from dirt. Shielding devices are available which are used for this purp ose. 5. Moisture: Moisture also affects the performance of electric motors. It greatl y contributes in the corrosion of the motor shafts, bearings and rotors. This ca n lead to an insulation failure also. The motor inventory should be kept dry all the time. 6. Vibration: There are a number of possible causes of vibration, such as misali gnment of the motor. Corrosion of parts can also cause the motor to vibrate. The alignment of the motor should be checked to eliminate this issue.

One of the keys to maximizing life in electric motors is to learn from your prema ture failures. Partner with a service shop and learn from the types of failures they see and document. Then, take actions to prevent these failures from happeni ng to your other motors in similar applications. This may involve changing your maintenance procedures. Perhaps you need to grease more or less, or use a more c ompatible grease. Perhaps you need to identify voltage supply problems (for inst ance, if you have bearing fluting from an adjustable speed drive). Second, check to see if contamination and water are getting into the motors. If e ither one of these is an issue, do you have the right enclosure? Does the enclos ure need a higher level of environmental protection? If so, look into severe dut y, IEEE 841 or washdown motors. Finally, if you want to maximize service life, empower the plant maintenance purchasing folks to buy better motors that will last longer and reduce energy nsumption for years. Buying the lowest-cost item doesn t always equate to the st life cost. Studies show that a motor s purchase price is only 2 percent of total life-cycle cost. For more information from Baldor, visit www.baldor.com. Emerson This reply comes from Jim Bryan, the product service group manager for Emerson M otor Technologies. To maximize motor life, focus on proper lubrication and temperature. In regard to proper lubrication, bearings must receive not only a good, quality l ubricant but the correct quantity at the proper intervals in order to obtain opt imum life and reliability. Under- or over-greasing can be detrimental to reliabi lity. Under-greasing does not provide the lubricant at the time it is needed, re sulting in bearing wear or heat damage. Over-greasing can damage shields or sign ificantly increase operating temperatures due to fluid shear friction. This redu ces the grease s lubricating capability. Oil-lubricated bearings must have the cor rect type and viscosity of oil for the same reasons stated previously. Closely f ollow manufacturer s recommendations for lubrication types, amounts and schedules. In regard to temperature, this is the nemesis of electric motors. Overload, under -voltage, over-voltage, unbalanced voltage and improper ventilation can all work to increase the motor s operating temperature. The overused rule of thumb is that motor life is cut in half for every increase of 10 degrees Celsius. Although th e rule s accuracy may be in question, it illustrates the point well. Any care give n to mitigate the operating temperature will be rewarded with increased life and and co lowe its

reliability. And, don t make the mistake of increasing the rated capacity of a mo tor applied in a high ambient temperature environment to accommodate the winding temperature increase. Particularly on enclosed machines, this could result in u nacceptable bearing operating temperatures, leading to early demise.