Motro & Drives - Winter Edition

Motors &
WINTER EDITION
Drives
Contents
3  How to match drives (VFDs, VSDs) to the motor

7  British Motor Manufacturer since 1947
8  How to field test 3-phase squirrel cage motors
17  10 essential maintenance and troubleshooting tips for
VFDs
21  Materials handling equipment
23  Motor repair answers via Virtual Training Day
29  Top 10 ways to protect your VFD investment
2
How to match drives (VFDs, VSDs)
to the motor  How to match drives
(VFDs, VSDs) to the
motor
Size a variable-speed drive (VSD) for the application, and ask if a general- British Motor Manufacturer
since 1947
purpose drive will do or if more embedded intelligence is needed. Do you
How to field test 3-phase
need a VSD, variable frequency drive (VFD) or adjustable speed drive (ASD)? squirrel cage motors
(Trick question)
10 essential maintenance
and troubleshooting tips
S ize the drive appropriately for an application. Also ask if a general-purpose drive for VFDs
will suffice, or if a drive with more embedded intelligence would fit the applica- Materials handling
equipment
tion? Set-up and troubleshooting advances will help too.
Motor repair answers via
Virtual Training Day
How to specify an ASD, VFD, VSD, inverter
Top 10 ways to protect
When specifying an adjustable speed drive (ASD) – also known as a variable-frequency your VFD investment
drive (VFD), variable-speed drive (VSD), and/or inverter – first look at the application
of the motor with which the ASD is to be used. Constant torque applications, such as
conveyors, lifting equipment, compressors, or crushers, among others, usually specify a
severe-duty or heavy-duty drive. In variable torque applications, which include centrifu-
gal fans and pumps, a normal duty drive will suffice.
Severe duty drives often have a current overload rating of 150% for two minutes and
can run continuously at 115% current. Drives with a heavy-duty rating have a current
overload of 150% for one minute and can run at 100% current continuously. Normal
duty drives are robust enough for fans and pumps since they have a current overload
rating of 120% for one minute and can also run at 100% current continuously.
3
How to match drives (VFDs, VSDs) to the motor
Confirm motor and  How to match drives

(VFDs, VSDs) to the
drive ratings motor
After matching a drive’s duty
British Motor Manufacturer
with its motor application, since 1947
one must always confirm the How to field test 3-phase

motor full load amps rating squirrel cage motors
and ensure it is less than or 10 essential maintenance

equal to the drive’s full load for VFDs
amps rating. Drives are cur-
Materials handling
rent-rated devices and should equipment
Figure 1: Constant torque applications include conveyors,
be sized by the full load am- compressors and hoists. Variable torque applications include pumps Motor repair answers via
perage and voltage rating, not and fans. Courtesy: Toshiba International Corp. Virtual Training Day
by horsepower. It is recom- Top 10 ways to protect

your VFD investment
mended to not use the motor’s service factor when sizing the drive full load amps with
the motor nameplate.
Fortunately, in today’s marketplace, general-purpose drives will include both a heavy

and normal duty rating in a single-drive unit. For example, a single drive will be rated
20 hp, heavy duty, with 150% overload, and also rated 25 hp, normal duty, with 120%
overload. Therefore, it will contain two full load amp ratings. An example would be
a 460-V drive with a nameplate reading “20HP HD/25HP ND” and “31.7A HD/39.2A
ND.” Drive programming allows users to specify whether the drive is in normal or
heavy-duty mode, choosing its amp and overload rating.
ASD, VFD, VSD, inverter industrial network communications

As the Industrial Internet of Things (IIoT) and control systems have become more ad-
4
vanced, ASDs have followed.  How to match drives

(VFDs, VSDs) to the
These same general-purpose
motor
drives will often include built-
in communication protocols, since 1947
such as EtherNet/IP (from
ODVA), Modbus TCP, and/or squirrel cage motors
Modbus RTU from Modbus 10 essential maintenance

Organization Inc., as more and troubleshooting tips
for VFDs
specifications require them.
Materials handling
Most drive manufacturers also equipment
offer add-on option cards for
many additional communica- Figure 2: Motor drive selection: To size the drive for the motor Virtual Training Day
consider motor full load amps, not the motor service factor.
tion protocols like Profibus from Top 10 ways to protect
Courtesy: Toshiba International Corp.
PI North America or DeviceNet your VFD investment
(ODVA). Drives with EtherNet/IP capabilities also will offer embedded web servers and
will be able use ASD software on a laptop or tablet. This allows for simpler commis-
sioning and real-time data monitoring.
Once a drive is chosen and ready to be

“This saves a lot of pro- installed, the best practice is to prepare
gramming time. Most drives before commissioning by knowing how the
require a method of starting drive will be controlled beforehand. This
and stopping.” saves a lot of programming time. Most
drives require a method of starting and stopping. Common methods include starting
and stopping via the keypad, the terminal strip with digital inputs, or communication
networks, like EtherNet/IP. In addition, they require a speed control method, also usu-
5
ally set via the keypad, terminal strip with analog or digital inputs, or communications  How to match drives
(VFDs, VSDs) to the
such as Modbus TCP.
motor

In the end, matching the drive with the motor’s application and knowing the control since 1947
methods will lead to a more efficiently run drive-motor system.
squirrel cage motors
Joshua Jagnanan is senior application engineer, low voltage adjustable speed drives, 10 essential maintenance
with the motors and drives division of Toshiba International Corp. Edited by Mark T. and troubleshooting tips
for VFDs
Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@
Materials handling
cfemedia.com. equipment

Joshua Jagnanan Virtual Training Day
Joshua Jagnanan, Toshiba International Corp. Top 10 ways to protect
your VFD investment
6
British Motor Manufacturer since 1947
How to match drives

(VFDs, VSDs) to the motor
 British Motor
Manufacturer since
1947
for VFDs
Materials handling

equipment


your VFD investment
British Motor Manufacturer since 1947
7
How to field test 3-phase squirrel
cage motors How to match drives

Maintenance of critical machines depends on the diagnostic electrical testing since 1947
of installed 3-phase squirrel cage motors, interpretation of results and key  How to field test
3-phase squirrel cage
points of physical inspection motors
E fficient, reliable operation of critical electric motors is top of mind for maintenance
professionals tasked with keeping production at optimum levels while avoiding
costly, unexpected shutdowns. Besides routine maintenance, this requires that criti-
for VFDs
Materials handling
equipment
cal motors be inspected and tested regularly. The focus of this article is on diagnostic
electrical testing of installed 3-phase squirrel cage motors, interpretation of results
and key points of physical inspection. Most of these tests and inspections also apply to
3-phase wound rotor motors and induction and synchronous generators. your VFD investment
Inspection and testing

Besides visual inspection, offline condition assessment and diagnostic tests for 3-phase
squirrel cage motors typically include insulation resistance (IR) and polarization index
(PI) or dielectric absorption ratio (DAR) tests. Depending on operating conditions and
availability of test equipment, offline testing and inspection also may include lead-to-
lead resistance and surge tests, sampling lubricating oil for analysis and checking for
soft-foot, output shaft runout and alignment of motor to driven equipment.
Inspection. The scope of the visual inspection will vary with the motor enclosure type.
If the motor’s interior is not accessible (e.g., no removable covers), carefully inspect
its external surfaces for wear, cracks and broken or missing hardware. Items to check
8
How to field test 3-phase squirrel cage motors
include the frame, feet, terminal box, fan covers, cooling fans and the output shaft and How to match drives
coupling or other shaft-mounted components.
since 1947
If the motor’s interior is acces-
sible, it may be possible to  How to field test
inspect the windings and other motors
internal components for defects 10 essential maintenance
or damage, including the air
for VFDs
gap between the rotor and the
Materials handling
stator (see Figure 1). A bore- equipment
scope and mirrors on extension Motor repair answers via
rods can probe recessed areas Virtual Training Day
like the rotor’s interior and the Top 10 ways to protect

space between the stator core your VFD investment
and frame to check for debris,

contamination, blocked venti-
lation ducts, cracked welds or a Figure 1: Stator coil damaged by short-circuit or inrush
current. Courtesy: EASA
loose fit of the rotor core to the shaft.
Record all damage and defects, remove debris and contamination and perform any
maintenance or repairs that need immediate attention. If necessary, schedule nones-
sential maintenance or repairs for the next regular shutdown.
Insulation resistance tests. The IR test is well a defined method of evaluating the
ground insulation of all types of motor windings (see Figure 2). It consists of applying
the test voltage and measuring the winding’s resistance to ground after one minute. IR
9
readings are temperature sensitive, so to be How to match drives

meaningful they should be corrected to the
standard temperature of 40° C (see Table 1). British Motor Manufacturer
since 1947
PI is an extension of the IR test and is calcu-  How to field test

lated by dividing the IR reading at 10 minutes motors
by megohm value at one minute. The rec- 10 essential maintenance
ommended minimum PI value for windings
for VFDs
rated Class B (130° C) and higher is 2.0, and
Materials handling
1.5 for Class A (105° C) windings. Windings equipment
with a lower PI value usually are unsuitable for Motor repair answers via
service. If the IR value is greater than 5,000 Virtual Training Day
megohms, per IEEE Std. 43 and IEC Std. Table 1: Recommend minimum insulation Top 10 ways to protect
60034-27-4, the PI value would not be meaningful, resistance values at 40° C (all values in your VFD investment
megohms) Courtesy: EASA
and the PI test need not be performed.
The PI test is most useful with stator form

coil windings (coils made with rectangular
or square wire). It may not be meaningful for
random-wound windings (coils made with
round wire) because the winding absorption
charging current decays within the first min-
ute or so of applied voltage. For those wind-
ings, the DAR is more useful, with a common
selection of IR readings taken at 30 seconds
10
Figure 2: Insulation resistance test of motor stator
and 60 seconds per IEC Std. 60034-27-4.
windings. Courtesy: EASA
Lead-to-lead resistance test. By comparing the phases or circuits in the winding, How to match drives
the lead-to-lead resistance test can detect high resistance joints in winding and lead
connections. Per CSA C392 and ANSI/EASA AR100, the resistance unbalance limit for British Motor Manufacturer
since 1947
random windings should be 2% from the average, and 1% from the average for form
coil windings.  How to field test
motors
Surge test. The surge test can detect turn-to-turn, coil-to-coil or phase-to-phase 10 essential maintenance
shorts. A common issue when surge testing an assembled motor is “rotor coupling”
for VFDs
— a magnetic interaction between a squirrel cage rotor and the stator winding that
Materials handling
can produce a dual trace of voltage as seen on the screen of a surge tester or an os- equipment
cilloscope. Turning the rotor a few mechanical degrees will merge the traces, unless Motor repair answers via
the winding has a fault or other defect (e.g., unbalanced winding circuits). Perform the Virtual Training Day
surge test only if the winding has an acceptable IR value and, if applicable, an accept- Top 10 ways to protect
able PI value. your VFD investment
Shaft runout test. Mechanical tests include the output shaft runout test, which uses
a dial indicator to measure shaft displacement at the end of the shaft (if possible) or
adjacent to the coupling during one revolution. NEMA Standard MG 1 (NEMA Std. MG
1) allows up to 0.003-inch (0.08 millimeter) total indicated runout (TIR) for shaft diam-
eters of 1.625 inch to 6.500 inches (41 to 165 millimeters). A more rigorous yet simpler
criteria is to limit runout to no more than 0.001 inch (0.025 millimeter) for 2-pole mo-
tors, 0.002 inch (0.051 millimeter) for 4-pole motors and 0.003 inch (0.076 millimeter) for
motors with six or more poles.
Online motor testing

Online (running) tests vary by machine type (e.g., squirrel cage induction, synchronous,
11
wound rotor). If the mo- How to match drives

tor can operate safely,
these may include mea- British Motor Manufacturer
since 1947
suring the starting (in-
rush) current, line-to-line  How to field test
voltages and voltage un- motors
balance. On large mo- 10 essential maintenance
tors or those powered
for VFDs
by variable-frequency
Materials handling
drives (VFDs), it also is equipment
important to check for Motor repair answers via
shaft currents. Figure 3: Asymmetrical offset of electric motor
inrush current. Courtesy: EASA Top 10 ways to protect

Inrush current test. Strictly speaking, inrush your VFD investment
is the asymmetrical dc offset that occurs in the first cycle, or few cycles, after an ac mo-
tor is energized (see Figure 3). According to NEMA Std. MG 1, the inrush current can be
1.8 to 2.8 times the locked-rotor current, which is typically six to eight times the full-load
current. Consequently, it could be as much as 22 (2.8 x 8) times the full-load current. For
a motor with a higher than typical locked-rotor current, it can be high enough to trip cir-
cuit breakers. When taking measurements, unless the ammeter can measure momentary
inrush (peak) current, it will only indicate the steady-state, locked-rotor current.
Line-to-line voltages test. Line-to-line voltages should be within 10% of the motor’s
rated voltage, according to NEMA Std. MG 1 and within 5% per IEC Std. 60034-1 (10%
for limited duration and frequency of occurrence). Too high a voltage can increase
heating of the motor’s magnetic core, while too low a voltage can reduce its torque
12
capability (see Table 2). There is no rule-of-thumb to estimate whether overvoltage will How to match drives
increase or decrease motor current, and likewise with undervoltage.
since 1947
Unbalanced voltage
test. Another factor  How to field test
related to voltage is motors
unbalanced voltage. 10 essential maintenance
According to NEMA Std.
for VFDs
MG 1, a motor should be
Materials handling
de-rated if voltage un- equipment
balance exceeds 1% — a Motor repair answers via
requirement often con- Table 2: Examples of how line voltage variation
fused with the tolerance for voltage variation affects temperature and efficiency. Courtesy: EASA Top 10 ways to protect
(see Figure 4). Utilities frequently limit the your VFD investment
voltage unbalance for the power they supply to 3%, which, according to NEMA Std. MG
1, would require derating horsepower by 12%. Since this often is impractical, many mo-
tors end up operating on unbalanced voltages with reduced output torque and increased
current. The higher current is especially significant because NEMA Std. MG 1 says current
unbalance with load can be six to 10 times the percent voltage unbalance. Applying this
rule to the 3% voltage unbalance, the current unbalance could be 18% to 30%.
Heating is a function of the power loss in a winding; specifically, the current squared
times the resistance (I2R). With 3% voltage unbalance, the highest current “leg” of
the winding may have about 18% more heating due to the associated current unbal-
ance. The additional heating is estimated by calculating twice the voltage unbalance
squared, in this case:
13
2 x 32 = 18% How to match drives

A thermal scan of the wind- British Motor Manufacturer

since 1947
ings, if accessible, can record
the actual temperatures re-  How to field test
sulting from unbalanced volt- motors
age and current conditions. 10 essential maintenance
for VFDs
Infrared thermographic
Materials handling
scanning of a motor’s exte- equipment
rior also can indicate areas Motor repair answers via
of abnormal heating (see Virtual Training Day
Figure 5). While there are no Top 10 ways to protect

specific temperature stan- your VFD investment
dards for the outer surface

(“skin”) of electric motors,
comparing a motor’s surface
temperature with iden- Figure 4: Derating for voltage unbalance per NEMA Std. MG 1. Courtesy: EASA
tical ratings under the
same or similar load conditions may reveal abnormal heating.
Shaft currents tests. Large motors and motors supplied by variable-frequency drives
(VFDs) should be checked for shaft currents (see Figure 6), even if none are suspected. In
large motors, for example, magnetic circuit dissymmetry due to segmented laminations
can induce shaft currents. Likewise, VFDs may link the rotor and stator by capacitive cou-
pling, creating circulating “shaft” currents that can cause premature bearing failure.
14
How to match drives


since 1947
 How to field test

motors
for VFDs
Materials handling
equipment
Figure 5: A motor driving a blower. Normal image on the left, thermal image on the right. Courtesy: EASA Motor repair answers via
Field testing is necessary to detect bearing currents from VFDs and some other causes. Top 10 ways to protect
your VFD investment
Measuring the current directly is not practical in this case, as it would require wrapping
a current transformer around the shaft inside the motor — i.e., between bearings. The
alternative is to measure the voltage from the frame to the shaft to determine if it is
enough to indicate damaging shaft currents.
A way to measure shaft voltage in the field is to attach one lead of a true root-mean-
squared (RMS) voltmeter to the frame (a grease fitting is a good location) and the other to
the shaft using a brush-like device (e.g., a fine copper wire such as a brush shunt) to drag
the shaft and sense the voltage. Directly sensing the voltage from the shaft with a meter
lead is not recommended because it typically will not maintain continuous contact.
If the sensed voltage exceeds 100 millivolts ac for rolling bearings or 200 millivolts ac
for sleeve bearings, damaging shaft currents are probably present. Another criterion
15
from NEMA Std. MG 1 says How to match drives

damaging shaft currents may
exist if the measured voltage British Motor Manufacturer
since 1947
between opposite ends of the
shaft exceeds 300 millivolts ac.  How to field test
motors
Final thoughts 10 essential maintenance
Field testing and inspection
for VFDs
of motors is an important part
Materials handling
of maintaining essential and equipment
often critical machines. Taking Motor repair answers via
time to learn about the prop- Virtual Training Day
er tests and procedures, and Top 10 ways to protect

how to apply them, will allow your VFD investment
you to improve reliability and

reduce costs.
Figure 6: Shaft current paths through an electric

motor. Courtesy: EASA
Thomas H. Bishop, P.E.
Thomas Bishop is a senior technical support
specialist at EASA Inc., St. Louis. EASA, a CFE Media content partner, is an internation-
al trade association of more than 1,800 firms in about 70 countries that sell and service
electromechanical apparatus.
16
10 essential maintenance and
troubleshooting tips for VFDs How to match drives

A properly maintained variable frequency drive (VFD) can provide decades since 1947
and cost-effective service. Making VFD inspections and maintenance part of How to field test 3-phase
facility oversight can improve outcomes.
 10 essential
maintenance and
T he manufacturing industry values variable frequency drives (VFDs) to maximize effi-

ciency and productivity, but that appreciation may slip away when a breakdown oc-
curs. A seamlessly functioning VFD delivers tremendous benefits, but it can falter when
troubleshooting tips
for VFDs
Materials handling
equipment
not adequately maintained. And when a production line or machinery grinds to a halt as
a result, it’s essential to troubleshoot the issues and quickly resume operations. Motor repair answers via
5 essentials of VFD maintenance Top 10 ways to protect

your VFD investment
To maximize VFD life expectancy, it’s crucial to support reliability through a proactive
maintenance plan. Such programs are tasked with underscoring the two foundational
principles of reliability.
• Enhancing failure-free conditions for the VFD

• Increasing the probability the VFD will enjoy uninterrupted function under proper
conditions.
For these principles to become a daily reality, it’s essential to understand the common
failures and how they occur. These issues include as reflected harmonics, energy spikes,
bearing problems and inadequate temperature controls.
In order to avoid having a VFD falter, it will be necessary to conduct the five following 17
10 essential maintenance and troubleshooting tips for VFDs
maintenance essentials. How to match drives

1. Keep the VFD clean: Commercial and industrial environments commonly include British Motor Manufacturer
since 1947
airborne dust and debris and can negatively impact a VFD. According to Factory-
Mation, regardless of the VFD chassis type, “It is critical that the heat sink and fans squirrel cage motors
are kept clean.” It’s recommended to periodically wipe, clean and air spray all accu-
mulations from the VFD.
 10 essential
maintenance and
2. Maintain VFD temperatures: It’s not unusual for VFDs to be housed in enclosures troubleshooting tips
for VFDs
that may experience heat spikes. Include temperature control systems and appro-
Materials handling
priate air circulation. equipment
3. Prevent moisture penetrations: Water and electricity do not mix well in industrial
settings. Moisture will inevitably cause corrosion, erratic behaviors, and equipment Virtual Training Day
failures. Keep the equipment dry. Top 10 ways to protect
4. Maintain tight connections: Vibrations tend to loosen electrical connections over your VFD investment
time. This may result in uneven VFD functions. Check the connections as part of an
ongoing maintenance plan.
5. Conduct visual inspections: The first step to proactive maintenance is to visually
inspect VFDs weekly. Have maintenance personnel look for the above-mentioned
issues and others that could impact VFD operations. Key elements to visually in-
spect include the connections, fiber optic cables, emergency circuits, and area
cooling systems, among others.
5 VFD troubleshooting tips to consider

While the best way to ensure a VFD does not needlessly falter is proactive maintenance,
breakdowns remain an industry reality. These may be caused by not recognizing environ-
mental effects on machinery, hard impacts or other unforeseen circumstances. Industry
18
leaders understand every minute an operation is How to match drives

not functioning at full capacity results in losses.
These five VFD troubleshooting tips can help British Motor Manufacturer
since 1947
get companies back online.
1. Check diagnostics display: Today’s VFDs
routinely come equipped with trouble-
 10 essential
maintenance and
shooting functions. The display module troubleshooting tips
for VFDs
can indicate issues such as overheating,
Materials handling
irregular voltage, or even a popped fuse. equipment
This is often the best place to begin The variable frequency drive category in the New
troubleshooting. Products for Engineers database has more than Virtual Training Day
50 entries. Courtesy: New Products for Engineers,
2. Check for moisture: Without making CFE Media and Technology Top 10 ways to protect
physical contact, take a visual inventory your VFD investment
of the machinery and look for moisture accumulations. Water can cause shorts and
other damage. Take safety precautions, and do not touch any electrical equipment
that may have gotten wet.
3. Check for dust: If the VFD has not been thoroughly cleaned, it may have grit
accumulations inside that caused a malfunction. In such cases, it may be neces-
sary to remove the unit and replace it until the affected VFD can be cleaned and
reinstalled. Organizations are wise to have backups in the event of a significant
breakdown or issue.
4. Check VFD connections: While wearing appropriate safety equipment, visually and
physically check for loose connections. If the VFD seemed to be delivering uneven
output recently, cable or connection problems may be the culprit.
5. Resonance testing: When vibrations place undue stress on equipment, they tend
19
to become increasingly unreliable. Issues may include impacted welds, and loose How to match drives
bolts, among others. Consider running a diagnostic test to see if the VFD is operat-
ing in what is called an “excited state” as a result of resonance. This troubleshoot- British Motor Manufacturer
since 1947
ing effort could save you from conducting repeat maintenance and replacement.
A properly maintained VFD can provide decades of cost-effective service. Like any piece
of equipment, though, that depends on maintenance and care. Making VFD inspections
 10 essential
maintenance and
and maintenance part of facility oversight can improve outcomes. troubleshooting tips
for VFDs
Materials handling
Lori Wade, a journalist from Louisville, submitted the article on behalf of FactoryMation, equipment
an automation distributor. Edited by Mark T. Hoske, content manager, Control Engineer- Motor repair answers via
ing, CFE Media, mhoske@cfemedia.com. Virtual Training Day

your VFD investment
Lori Wade
Lori Wade for FactoryMation.
20
Materials handling equipment
I f your business involves manufacturing, warehousing or distribution, materials han- How to match drives
dling is something you probably live and breathe every day. The smooth running of
any warehouse or factory operation depends on raw, component and finished materials
since 1947
being processed efficiently and safely and getting this right can help a business gain a
real competitive advantage. squirrel cage motors
We live in a 24-hour economy and intrinsic to a successful ‘always-on’ operation is an effi- and troubleshooting tips
for VFDs
cient process supported by the right equipment. Materials handling equipment comes in
many varieties; from hand-operated units through to specialised motorised systems for  Materials
equipment
handling
handling drums, reels, packages and glass. The right handling equipment, positioned
correctly in a process workflow, can save a business time, increase productivity and main- Virtual Training Day
tain health and safety.
your VFD investment
Packline Materials Handling has been designing and manufacturing lifting and handling
equipment since 1993 from its headquarters in Poole, UK. The company’s ‘Compac’
range of stainless-steel roll, reel and drum handling equipment is ideally suited to clean
room environments and Packline has established itself as the leading supplier of ma-
terials handling equipment to the food, drinks, dairy, pharmaceutical and medical pro-
cessing industries. The company has earned an enviable reputation around the world
for developing custom materials handling solutions that enable Packline customers to
improve productivity and enjoy a real competitive advantage.
Packline initially contacted Parvalux during 2006 seeking a new drive system partner. To
meet the performance specification needed in Packline’s product range, a number of
modifications were made to the Parvalux PM50-63 DC motor and GB4 gearbox combi-
nation and a sample was built and sent to Packline for testing and evaluation by their
21
Materials handling equipment
How to match drives


since 1947

for VFDs
 Materials
equipment
handling


your VFD investment
development team. This combination has proven to be highly successful, underlining

the capability and reliability of the Parvalux drive unit and it remains specified by Pack-
line to this day.
Packline’s Managing Director, Paul Winter, says; “We’ve worked with Parvalux for a number
of years now and they are a partner we trust. They take the time to understand what we’re
trying to achieve and have developed excellent drive solutions that enhance the ‘reliability
comes as standard’ message every Packline customer has come to expect from our brand.”
To find out more about Packline, please visit the company’s website: https://www.pack-
line.co.uk/ 22
Motor repair answers via Virtual
Training Day How to match drives

Motor repair advice about applications, a motor detective story, and a since 1947
common misconception about motor designs are among additional answers How to field test 3-phase
available after a motor repair educational course.
T
rends on motors and drives were covered in the CFE Media & Technology Virtu- for VFDs
al Training Day on Aug. 19, providing online training; the instructor for one of the
Materials handling
courses answers additional questions about motor repairs. Four courses offer potential equipment
for four approved learning units with four courses:
 Motor repair answers
via Virtual Training
Day
• What to know when repairing electric motors
• How to specify motors for more efficient HVAC systems
your VFD investment
• Introduction to motors and drives
• How to design hospital, health care facility HVAC systems.
Motor repair application, motor designs, motor detective

stories
Thomas Bishop, PE, senior technical support specialist, EASA, gave 45 minutes of in-
struction on motor repairs followed by more than 15 minutes of questions and answers.
The information will be available at www.controleng.com/online-courses until Nov. 30,
2020. Answers to unanswered questions follow.
Are there certain applications that have particular motor repair concerns?
Applications with higher than normal mechanical stress or in harsh environments may re- 23
Motor repair answers via Virtual Training Day
quire additional repair steps. For How to match drives

applications with higher stress,
such as a rock crusher, mechani- British Motor Manufacturer
since 1947
cal components such as the shaft
need closer inspection to check squirrel cage motors
for bending or cracks. Harsh
environments such as outdoors and troubleshooting tips
for VFDs
near the ocean with its salt water
can lead to extensive corrosion Materials handling
Thomas Bishop, PE, is senior technical support specialist, EASA. equipment
damage. Applying overcoating
with epoxy materials would prob-
He offered information about motor repairs in a Aug. 19 one-
hour course available for viewing until end of November 2020.  Motor repair answers
ably be called for to reduce the Courtesy: CFE Media and Technology and EASA Day
effects of corrosion. Top 10 ways to protect
your VFD investment
Do more recent motor designs extend motor life over earlier generations? How?
The short answer is “no.” As energy efficiency of motors has increased, a popular mis-
conception is that motor design life has also increased. However, the factors that affect
motor thermal life, such as winding temperature, for the most part haven’t changed; and
the bearings and mechanical systems are still the same.
Can you share a useful “detective story” about motor repairs?
An end user had a motor in a centrifugal pump application and when it required service
center repairs, it was found the shaft had a crack in it. The pump application would not
have caused a mechanical shock that could explain the cracked shaft, and the next sus-
24
picion was the shaft material had an inherent flaw in it. A root cause analysis (RCA) was How to match drives
performed and what was found was the motor had been used in a severe mechanical
shock application, a shredder subject to overload, and that the crack occurred in that British Motor Manufacturer
since 1947
prior application.
Motor repairs: More questions and answers 10 essential maintenance
Questions below were among those covered in the live question and answer session and and troubleshooting tips
for VFDs
included here to encourage others to listen to the presentation archive.
Materials handling
equipment
The repair or replace flow chart in your presentation, was very useful, thanks. Are
there EASA-recommend best practices to avoid unscheduled motor breakdowns?  Motor repair answers
With highest-performing critical rotating assets, should we consider installing net- Day
worked sensors and monitoring analytics? Top 10 ways to protect
your VFD investment
A broad-based document is EASA’s “Getting The Most From Your Electric Motors,”
which is available as a free download from the EASA website. More motor manufactur-
ers and others are getting into the Industrial Internet of Things (IIoT) and are providing
real-time monitoring of motors and other rotating equipment.
Do the 1997 or 2007 efficiency laws you mentioned require motor replacements
instead of repairs in any situations?
Neither regulation mandates motor replacement.
Thanks for the research showing no significant efficiency degradation on repair of

premium efficiency motors. Do motor service centers need any special training or
25
skills to work on NEMA Premium or IE-3 motors? How to match drives

From a technical perspective, the repairs to premium efficiency motors are no different British Motor Manufacturer
since 1947
than their predecessors. The most significant differences are that premium efficiency mo-
tors tend to be heavier due to longer cores; and sometimes also physically longer over- squirrel cage motors
all. The heavier weight and longer physical size can, at times, present issues replacing a
lighter and shorted motor. and troubleshooting tips
for VFDs
Is data in the ¼ million EASA windings database being used for predictive mainte- Materials handling
equipment
nance or other automated analytics efforts? (A couple years ago, I heard an analyt-
ics software company bought a motor services company primarily for its data.)  Motor repair answers
Day
The data is winding data, such as was shown in slide 31. I don’t think anyone would pur- Top 10 ways to protect
chase a service center to gain access to this database, but it could add to the value of a your VFD investment
service center was being sold.
Do windings naturally degrade over time following a pattern?
There is a guideline rule for thermal degradation of windings: winding life is halved for
every 10 degrees C increase in temperature. As part of the inspection process, service
center technicians view the condition of the windings. Even though a winding passes
electrical tests, it may have evidence of overheating (discoloration) or contaminants that
have adhered to the winding, creating a thermal blanket (a recent case was a winding
coated with cement), and that can’t be removed without damaging the winding.
What are some common misconceptions about motor repairs?

26
Probably the most common misconception, and one that we have addressed in today’s How to match drives
session, is that motor repair degrades efficiency. Based on the factual information pro-
vided in the session it should be clear that repairs using good practices can not only British Motor Manufacturer
since 1947
maintain motor efficiency, but also maintain motor reliability.
Do you have additional advice or recommendations regarding motor repairs?
for VFDs
As the end user, check to be certain that the service center performing your repairs
follows the good practices in ANSI/EASA AR100, and if the service center is EASA Ac- Materials handling
equipment
credited, that is further assurance they do. Although it may not be possible do so in the
present pandemic, take a tour of your service center. You will gain a better appreciation  Motor repair answers
of the work that goes into motor repair, and take a good look at a rewind in progress. Day
The details and intricacies of winding insertion are rather fascinating, if not amazing. Last Top 10 ways to protect
but not least, perform predictive and preventive maintenance on your motors to extend your VFD investment
the mean time between failures (MTBF).
Thomas Bishop, PE, is senior technical support specialist, EASA. Edited by Mark T.
Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@
cfemedia.com, who served as moderator for the session.
Thomas H. Bishop, P.E.

Thomas Bishop is a senior technical support specialist at EASA Inc., St. Louis. EASA, a
CFE Media content partner, is an international trade association of more than 1,800 firms
in about 70 countries that sell and service electromechanical apparatus.
27
Top 10 ways to protect your VFD
investment How to match drives

Variable speed drives offer savings, if used properly since 1947

Manufacturers improve efficiency using variable speed drives for electrical motors. Com-
pared to across the line starters or older DC drives, variable AC drives can save users 10 essential maintenance
money by providing better motor control to operate the system at lower speeds and uni- for VFDs
ty power factor. Over time, the payback from these savings reduces operating costs and Materials handling
provides a return on investment. However, this is only possible by ensuring the lifecycle equipment
of these units are maximized and optimized. Motor repair answers via
Here are ten ways to protect your investment in a variable frequency drive (VFD):  Top 10 ways to
protect your VFD
investment
1. Know your application. Protecting VFD investment begins prior to the actual pur-
chase. Factors such as performance, speed or torque control, fieldbus communica-
tions, or even inputs and outputs can often affect the model of unit you will need.
Taking the time to first determine actual needs before the purchase can often dif-
ferentiate between a successful project and one that keeps maintenance personnel
up in the middle of the night.
2. Engineer the system properly. The VFD needs to be sized according to load and
ambient conditions to ensure that it can handle the torque required in all situations.
Be sure to consult with the VFD manufacturer, which will have design resources
available for support.
3. Evaluate at your environment. If it is contaminated with dust, conductive residue, 29

Top 10 ways to protect your VFD investment
debris, moisture, oil, high temperatures, or other potential disruptors, you may want How to match drives
to invest in a VFD that is rated NEMA 12 or NEMA 4 to protect it from these vari-
ables. Also consider temperature, altitude, and humidity and compare them to the British Motor Manufacturer
since 1947
manufacturer’s specifications. The electrical environment is also important and often
overlooked; existing harmonics, stray voltages, imbalances, or line spikes can cause squirrel cage motors
adverse effects to your new installation. Filters, reactors, and isolation transformers
are other items that may be needed to ensure a properly operating environment. and troubleshooting tips
for VFDs
4. Select the correct motor. Not all motors are created equal. Due to the nature of Materials handling
equipment
the pulse-width modulation (PWM) waveform that a VFD generates to produce a
synthetic AC waveform, there are often high voltage spikes. VFD-rated motors are Motor repair answers via
equipped with extra insulation and are designed to handle this. Be sure to con-
sult with the motor manufacturer regarding speeds, duty cycle, isolated bearings,  Top 10 ways to
protect your VFD
ground brushes, and environment. A good motor manufacturer will work to verify investment
you are purchasing the best product for the application.
5. Specify the correct fusing, cabling, and filters. Before finalizing the installation, be
sure to consult the installation manuals which come with the VFD. They provide
valuable information regarding compliant fuses and cables sizes and types (such
as VFD cable), as well as any external items you may need such as a load reactor to
prevent things like reflective waves. Further, use the correct wiring and wiring prac-
tices during the installation process. A VFD cannot maintain its NEMA 12 or NEMA
4 rating if wiring practices and components of the same rating are not used.
6. Use trained and qualified professionals to install the equipment, especially in harsh
30
environments. Manufacturers provide minimal standards for installation and often How to match drives
there are local electrical regulations which also need to be met. Further, a trained
and qualified installer will be able to ensure that drives are mounted correctly, all British Motor Manufacturer
since 1947
wiring is bonded and grounded properly, the installation allows for proper airflow,
and all covers and protective barriers have been reinstalled correctly. squirrel cage motors
7. Verify that those doing the start-up and commissioning are well-versed in VFD op- and troubleshooting tips
eration. Knowing and understanding how to properly enter the motor data, utilize for VFDs
PID controls, and establish field bus communications will help assure that you meet Materials handling
equipment
both budgets and deadlines during the installation.
8. Invest in training. Having a good working comprehension of variable AC drives will
help you and maintenance staff to better understand what is considered normal and  Top 10 ways to
protect your VFD
abnormal operation. By identifying abnormalities early, you could prevent unexpect- investment
ed failures and downtime and be able to better help troubleshoot when the unex-
pected does occur.
9. Perform regular maintenance. Like most electrical equipment, VFD manufacturers

prescribe recommended maintenance intervals which should be followed. This will
allow you to planned shut-down times to clean and inspect your unit, identify poten-
tial problems, and remove any items which may be preventing your equipment from
properly dissipating heat. Also it allows you to chart standard operating conditions
and identify if things are starting to break down, such as your electrolytic capacitors.
10. Invest in recommended spare parts and review them on a regular basis. It is one
thing to purchase a spare unit, and another to use it. Many VFDs today have electro-
lytic capacitors, which, if left unused for more than a year, begin to deteriorate. This
31
may cause the unused drive to spontaneously combust when finally installed. While How to match drives
it is important to have extra parts like fuses and control boards, as well as spare
VFDs, on hand, it is just as important to regularly test and inspect them to ensure British Motor Manufacturer
since 1947
they are in good operating condition and ready for use.
It’s important to realize that anyone can purchase a VFD and install it; however, it is im-
perative that the installation process be followed precisely. By spending the necessary and troubleshooting tips
for VFDs
time up front, investing in the correct products for your application, and by conducting
regular maintenance, you will reap the energy savings and operational efficiencies of a Materials handling
equipment
VFD for many years to come.
Jon Mosterd
Jon Mosterd is engineering manager, North America Center of Excellence, Danfoss
 Top 10 ways to
protect your VFD
Drives. investment
32
Motors & Drives
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Motors &

3  How to match drives (VFDs, VSDs) to the motor

Confirm motor and  How to match drives

one must always confirm the How to field test 3-phase

and ensure it is less than or 10 essential maintenance

by horsepower. It is recom- Top 10 ways to protect

Fortunately, in today’s marketplace, general-purpose drives will include both a heavy

ASD, VFD, VSD, inverter industrial network communications

vanced, ASDs have followed.  How to match drives

Modbus RTU from Modbus 10 essential maintenance

Once a drive is chosen and ready to be

British Motor Manufacturer

Motor repair answers via

How to match drives

Motor repair answers via

Top 10 ways to protect

British Motor Manufacturer since 1947

British Motor Manufacturer

Inspection and testing

like the rotor’s interior and the Top 10 ways to protect

and frame to check for debris,

readings are temperature sensitive, so to be How to match drives

PI is an extension of the IR test and is calcu-  How to field test

The PI test is most useful with stator form

Online motor testing

wound rotor). If the mo- How to match drives

inrush current. Courtesy: EASA Top 10 ways to protect

2 x 32 = 18% How to match drives

A thermal scan of the wind- British Motor Manufacturer

Figure 5). While there are no Top 10 ways to protect

dards for the outer surface

How to match drives

British Motor Manufacturer

 How to field test

from NEMA Std. MG 1 says How to match drives

er tests and procedures, and Top 10 ways to protect

you to improve reliability and

Figure 6: Shaft current paths through an electric

British Motor Manufacturer

T he manufacturing industry values variable frequency drives (VFDs) to maximize effi-

5 essentials of VFD maintenance Top 10 ways to protect

• Enhancing failure-free conditions for the VFD

maintenance essentials. How to match drives

5 VFD troubleshooting tips to consider

leaders understand every minute an operation is How to match drives

Top 10 ways to protect

How to match drives

British Motor Manufacturer

How to field test 3-phase

Motor repair answers via

Top 10 ways to protect

development team. This combination has proven to be highly successful, underlining

British Motor Manufacturer

Motor repair application, motor designs, motor detective

quire additional repair steps. For How to match drives

Can you share a useful “detective story” about motor repairs?

Neither regulation mandates motor replacement.

Thanks for the research showing no significant efficiency degradation on repair of

skills to work on NEMA Premium or IE-3 motors? How to match drives

service center was being sold.

Do windings naturally degrade over time following a pattern?

What are some common misconceptions about motor repairs?