Section 10 — On-Site Troubleshooting Fundamentals of DC Operation and Repair Tips

field connections. It is likely that the shunt fields are con-

nected for either double, or half, the rated voltage.
Many generator applications include a rheostat for simple
regulation of the generator output voltage. Check the con-
dition of the rheostat for shorts or opens. A simple procedure
for doing so is to connect an ohmmeter to the rheostat “start”
and “finish” terminals and then observe the resistance while
adjusting the rheostat through its full range. The resistance
should change smoothly, with no sudden swing in resis-
tance. If the rheostat is open or shorted, it must be replaced.
Be sure the replacement rheostat is rated for the field
current.
If the generator is compound wound, determine whether
it should be connected cumulative or differential. Certain
applications, such as the swing generator of a dragline,
must be connected differentially. If a generator application
calls for cumulative connection, a differential connection will
cause a dangerous loss of output voltage should the gen-
erator suddenly cease to produce voltage when the load is
critical.
If the armature was rewound, the connection may be
incorrect. For example, an armature that was connected
duplex but should be simplex.

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Fundamentals of DC Operation and Repair Tips Failure Analysis — Section 11

11
Failure Analysis
Section Outline Page
Summary of stresses .................................................................................................................................... 11-2
Root cause methodology .............................................................................................................................. 11-3
Root cause methodology forms .................................................................................................................... 11-5
Photos of armature failures ........................................................................................................................... 11-8
Guide to commutator appearance ............................................................................................................... 11-10
Photos of commutator failures .................................................................................................................... 11-11
Photos of brush and brushholder failures ................................................................................................... 11-12
Photos of field coil, series and interpole failures ......................................................................................... 11-13
Photos of compensating winding failures .................................................................................................... 11-14
Appearance of the most common shaft failures .......................................................................................... 11-15
Photos of shaft failures ................................................................................................................................ 11-16
Photos of bearing failures ........................................................................................................................... 11-18
Photos of mechanical failures ..................................................................................................................... 11-20

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Section 11 — Failure Analysis Fundamentals of DC Operation and Repair Tips

SUMMARY OF STRESSES Some of the stresses acting on the components of a DC

Most motor failures are caused by a combination of motor include:
stresses acting upon the motor and the system it is attached
to. ARMATURE
If these stresses remain within the design capabilities of • Thermal stress
the system, premature failure should not occur. However, if Overload, stall, hot spots, poor ventilation.
any combination of them exceeds the design capacity, the • Electrical stress
life of the motor or system may be drastically reduced and • Mechanical stress
a catastrophic failure could occur. Loose lamination-to-shaft fit.

FIGURE 1: TYPICAL DC MOTOR SYSTEM

Ambient
• Moisture
• Chemical
• Temperature
• Airflow (cfm)
• Vibration
• Noise
• Wind, snow, rain

Power supply Electricity

Power source
• Utility
• Co-gen Motor

Motor controls
• DC drive
Shaft couplings • M-G set
• Sensors
Couplings • Metering
• Belting
• Direct connect
• Clutch
• Gears
Mounting base
• Plate
• Rails
• C-face
Mechanical system • P-base
Process
Mechanical device
• Pump Process requirement
• Fan • Flow
• Compressor • Mixing
• Mechanical • Grinding
• Transmission drive • Handling
• Dragline • Conveyance
• Extruder • Mining

When conducting a root cause failure analysis, it is important to recognize that the motor is only one component of a system.
Many factors affecting the system will also affect the motor and may contribute to motor failure. Of course, motor failure
could also cause other system components to fail. This illustration shows a typical system. Note that it also includes the
process requirement.

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Fundamentals of DC Operation and Repair Tips Failure Analysis — Section 11

• Dynamic stress
Vibration, transient torque, centrifugal force.
TABLE 1: MOTOR COMPONENTS/STRESSES
• Environmental stress Frame/
Contamination (carbon), abrasion, obstructed Types of Armature end
stresses assembly Fields Bearings Shaft bracket
ventilation.
Thermal X X X X X
FIELD COILS, INTERPOLES, SERIES FIELDS AND Electric/
COMPENSATING WINDINGS dielectric
X X X
• Thermal stress Mechanical X X X X X
Overload, blower/ventilation problems, inhibited
heat transfer. Dynamic X X X X
• Mechanical stress Vibration/
X X X X X
Loose coils, fasteners, material deviation, im- shock
proper design or manufacturing process. Residual X X
• Dynamic stress
Electromagnetic X X X X
Vibration.
Environmental X X X X X
• Environmental stress
Contamination (carbon), abrasion.
• Mechanical
Stresses resulting from manufacturing or assem-
BEARING STRESSES
bly processes, poor fit between end bracket and
• Dynamic/static loading
frame.
Radial, axial or pre-load.
• Dynamic
• Thermal
Vibration, shock and torsional cycling.
Friction, lubricant and ambient.
• Residual
• Vibration and shock
“Soft feet,” welding stresses from manufacturing
Armature, driven equipment or system. process.
• Electrical currents • Environmental
Armature dissymmetry, electrostatic coupling, Corrosion, moisture and erosion.
static charges and DC drives.
Table 1 summarizes the main stresses that can affect DC
• Environmental machines.
Condensation, foreign materials, excessive
ambient and restricted ventilation.
• Mechanical
ROOT CAUSE METHODOLOGY
Given the combination of stresses on a motor and sys-
Loss of clearances, misalignment, and shaft and
tem, two methods of analysis are effective for determining
housing fits.
the root cause of failure. The first deals with failure modes/
classes and failure patterns. These are shown in Table 2
SHAFT STRESSES and can be used as a checklist for inspecting a failed motor.
• Mechanical The second category deals with the appearance, applica-
Overhung, torsional and axial loads. tion and maintenance history of the motor. A methodology
• Dynamic checklist begins on Page 11-5.
Cyclic and shock.
• Residual APPEARANCE OF MOTOR AND SYSTEM
Manufacturing and repair processes. This section focuses on the second part of the methodol-
ogy, gathering critical information pertaining to the
• Thermal
appearance, application and maintenance history of the
Temperature gradients and armature bowing. motor and related equipment. Combining this information
• Environmental with the class and pattern of failure usually will give a clue
Corrosion, moisture, erosion, wear and cavitation. about the cause of failure.
• Electromagnetic Use the following checklist to evaluate the condition of the
Side loading. motor. Note that some questions overlap.
• Is any foreign material present?
FRAME/END BRACKET STRESSES • Are there any signs of blocked ventilation passages?
• Thermal • Are there signs of overheating? Check insulation, lamina-
Distortion due to thermal expansion. tions, armature, commutator, bearings, lubricant, painted
surfaces, etc.

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Section 11 — Failure Analysis Fundamentals of DC Operation and Repair Tips

• Has the armature lamination or shaft rubbed? Record all

locations of contact. TABLE 2: METHODOLOGY
• Are the armature cooling passages free and clear of Motor Failure
clogging debris? component mode/class Failure pattern
• Are the bearings free to rotate and operate as intended? Armature Shaft Thermal
• Are there any signs of moisture on the frame, rotating assembly Bearing Magnetic
assembly, bearing system or any other parts? Lamination Residual
• Are there any signs of movement between armature and Coils and Dynamic
shaft or commutator and shaft? commutator Mechanical
• Is the lubrication system as intended or has the lubricant Vent. system Environmental
leaked or deteriorated? Fields Shunt Thermal
• Are any mechanical parts missing, such as balance Series Mechanical
weights, bolts, fan blades, etc., or has any contact oc- Interpole Dynamic
curred between rotating parts that should maintain a Compensating Environmental
clearance?
Ball Fatigue spalling Thermal
• What is the condition of the coupling device, driven bearings Fretting Vibration/noise
equipment, mounting base and other related equipment? Smearing Lubricant quality
• What is the condition of the bearing bore, shaft journal, Skidding Lubricant quantity
seals, shaft extension, keyways and bearing caps? Wear Mounting/fits
• Is the motor mounted, aligned and coupled correctly? Lub. failure Contamination
• Is the ambient usual or unusual? Electric pitting Mech. damage
• Do the locations of stress risers show signs of weakness Fluting Electrical damage
or cracking? (The driven end shaft keyway is a weak link.) Cracks Load pattern
Seizures
When analyzing motor failures, it is helpful to photograph
the motor and indicate the point where the failure occurred Shaft Overload Ductile
as well as the relationship of the failure to both the rotating Fatigue Brittle
and stationary parts, such as shaft keyway, etc. Pictures are Corrosion Beach marks
worth a thousand words. Conchoidal marks
Chevron marks
Ratchet marks
APPLICATION CONSIDERATIONS
Cup/cone
Usually it is difficult to reconstruct conditions at the time Shear lips
of failure. However, a knowledge of the general operating Fretting
conditions will be helpful. Consider the following items:
Frame/ Frame Thermal
• What are the load characteristics of the driven equipment
end bracket End bracket Residual
and the loading at the time of failure?
Bearing retainer Vibration/shock
• Does the load cycle or pulsate? Mounting feet or Mechanical
• Have any other motors or equipment failed on this appli- flange Environmental
cation?
• How many other units are successfully running? • Have any other motor failures been recorded? If so, what
• How long has the unit been in service? was the nature of the failures?
• What type of protection is provided? • What failures of the driven equipment have occurred?
• What removed or tripped the unit from the line? • Was any welding done recently near the motor?
• Where is the unit located and what are the normal • When was the last time any service or maintenance was
environmental conditions? What was the environment at performed?
time of failure? • What operating levels (temperature, vibration, noise,
• What was the ambient temperature around the motor at insulation, resistance, etc.) were observed prior to the
time of failure? Any recirculation of air? Is the exchange failure?
of cooling air adequate? • What comments were received from the equipment op-
• How would you describe the driven load method of erator regarding the failure or past failures?
coupling and mounting? • How long was the unit in storage or sitting idle?
• What were the storage conditions?
MAINTENANCE HISTORY • How often is the unit started? Were there shutdowns?
Past performance of the motor often can provide clues • Were correct lubrication procedures utilized?
about the cause of the problem. Again, a checklist may be • Have changes been made to surrounding equipment?
helpful. Consider the following:
• Are the pulleys positioned on the shaft correctly and as
• How long has the motor been in service? close to the motor bearing as possible?

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Fundamentals of DC Operation and Repair Tips Failure Analysis — Section 11

ROOT CAUSE METHODOLOGY FORM

APPEARANCE OF MOTOR AND SYSTEM

ITEM REMARKS

• Is any foreign material present?

• Are there any signs of blocked ventilation passages?

• Are there signs of overheating exhibited by insulation,

laminations, commutator, bearings, lubricant, painted
surfaces, etc.?

• Has the armature lamination or shaft rubbed? Record all

locations of armature and field pole contact.

• Are the topsticks, coils or coil bracing loose?

• Are the armature cooling passages free and clear of

clogging debris?

• What is the physical location of the winding failure? Which

winding failed (e.g., armature, fields, interpoles)?

• Are the bearings free to rotate and operate as intended?

• Are there signs of moisture on the frame, rotating assem-

bly, bearing system or any other parts?

• Are there any signs of movement between armature and

shaft or commutator and shaft?

• Is the lubrication system as intended or has there been

lubricant leakage, deterioration or overlubrication?

• Are any mechanical parts missing, such as balance

weights, bolts, armature teeth, fan blades, etc., or has any
contact occurred between rotating parts that should main-
tain a clearance?

• What is the condition of the coupling device, driven

equipment, mounting base and other related equipment?

• What is the condition of the bearing bore, shaft journal,

seals, shaft extension, keyways and bearing caps?

• Is the motor mounted, aligned and coupled correctly?

• Is the ambient usual or unusual?

• Do the stress risers show signs of weakness or cracking?

(The driven end shaft keyway is a weak link.)

• Does the commutator film appear normal? If not, describe

its appearance.

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Section 11 — Failure Analysis Fundamentals of DC Operation and Repair Tips

ROOT CAUSE METHODOLOGY FORM

APPLICATION CONSIDERATIONS

ITEM REMARKS

• What are the load characteristics of the driven equip-

ment and the loading at time of failure?

• Does the load cycle or pulsate?

• Have any other motors or equipment failed on this

application?

• How many other units are running successfully?

• How long has the unit been in service?

• What type of protection is provided?

• What removed or tripped the unit from the line?

• Where is the unit located, and what are the normal

environmental conditions? What was the environment
at the time of the failure?

• What was the ambient temperature around the motor at

the time of the failure? Was there any recirculation of
air? Is the exchange of cooling air adequate?

• Was power supplied by a drive or an M-G set?

• How would you describe the driven load method of

coupling and mounting?

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Fundamentals of DC Operation and Repair Tips Failure Analysis — Section 11

ROOT CAUSE METHODOLOGY FORM

MAINTENANCE HISTORY

ITEM REMARKS

• How long has the motor been in service?

• Have any other motor failures been recorded? If so,

what was the nature of the failures?

• What failures of the driven equipment have occurred?

Was any welding done?

• When was the last time any service or maintenance

was performed? When was the last time new brushes
were installed?

• What operating levels (temperature, vibration, noise,

insulation, resistance, etc.) were observed prior to the
failure?

• What comments were received from the equipment

operator regarding the failure or past failures?

• How long was the unit in storage or sitting idle prior to

starting?

• What were the storage conditions?

• How often is the unit started? Were there shutdowns?

• Were correct lubrication procedures used?

• Have any changes made been to surrounding equip-

ment?

• What procedures were used in adjusting belt tensions?

• Are the pulleys positioned on the shaft correctly and as

close to the motor bearing as possible?

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Section 11 — Failure Analysis Fundamentals of DC Operation and Repair Tips

ARMATURE FAILURES

This armature was oversped when the field circuit opened.

This armature failed when the banding material deterio-

rated. Humid salt air weakens fiberglass banding. A
high resin-content banding works best in humid condi- The thermal pattern clearly shows evidence that the fan
tions. end has been much hotter than the commutator end.

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Fundamentals of DC Operation and Repair Tips Failure Analysis — Section 11

ARMATURE FAILURES

On larger machines, some manufacturers install equaliz-

ers on the opposite commutator end to facilitate
replacement. When equalizers are installed behind the
commutator, the armature has to be rewound if equalizer
damage occurs. Common equalizer problems include
This coil extension shows evidence of rapid thermal carbon shorting, vibration and movement.
stress.

Surge rope is sometimes used as lacing in order to brace

the risers and increase rigidity. These freestanding risers are not braced. They are prone
to flex and move during rapid acceleration or decelera-
tion. A row of rigid lacing at mid-height would reduce
flexing.

Flashover damaged the armature banding. Sudden re-

versal, caused by incorrect drive settings, was the root If spaced uniformly, these coils would have better expo-
cause. sure to airflow.

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Section 11 — Failure Analysis Fundamentals of DC Operation and Repair Tips

GUIDE TO COMMUTATOR APPEARANCE

Light film Medium film Heavy film
Uniform tan to charcoal-brown film Copper oxide film may show faint Uniform, even heavy film coating may
of copper oxide on the commutator streaks on machines that are not be cause for alarm, if there are no
indicates proper operation. running properly. unusually dark or worn areas.

Streaking Slot bar marking

If a motor has been in service A darker film appears on bars in
for years and streaking has not a definite pattern related to the
progressed, it is not considered number of armature conduc-
harmful. If a newly-installed tors per slot.
motor shows streaking, monitor it carefully. Streaking Possible causes
may progress to threading. • Electrical adjustment (neutral, interpole strength)
• Electrical overload
Threading • Lubricant or chemical contamination
Fine lines result when excessive
metal transfer occurs. Usually
leads to resurfacing of commu- Pitch bar marking
tator and rapid brush wear. This produces low or burned
Possible causes spots on the commutator sur-
• Light electrical load face that equal half or all the
• Light brush pressure number of poles on the motor.
• Porous brush Possible causes
• Lubricant or chemical contamination • Armature connection
• Unbalanced shunt field
Bar edge burning • Light brush pressure
This is an abnormal buildup of • Vibration
commutator material, forming • Abrasive brush
most often at the trailing edge of
the bars. This condition can Copper drag
cause flashover if not checked. Excesive amount of commuta-
Possible causes tor material at the trailing edge
• Electrical adjustment (neutral, interpole strength) of the bars. Flashover could
• Light brush pressure occur if not corrected.
• Vibration Possible causes
• Abrasive brush or wrong brush grade • Vibration
• Armature winding fault • Light brush pressure
• High mica • Chemical contamination
• Oversized brushholder • Abrasive brush
• Lubricant, chemical or abrasive dust contamination
Stall condition
Grooving Footprint of each brush at regu-
This is a mechanical condition lar intervals that coincides with
caused by abrasive material in brush spacing.
the brush or atmosphere. Possible causes
Possible causes • Mechanical jam
• Abrasive brush • Operator inexperience
• Abrasive dust contamination • Severely overloaded motor

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Fundamentals of DC Operation and Repair Tips Failure Analysis — Section 11

COMMUTATOR FAILURES

This banded commutator has an uncommon failure.

Carbon or moisture trapped under the band of the af-
fected bar has completed the circuit to ground.

Grooving is caused by abrasive wear by either dust in the

atmosphere or too abrasive a brush grade. Two major
problems are associated with grooving:
• It diverts pressure from the relatively flat bottom to
the radiused sides of each groove. Reduced brush
pressure increases the brush temperature.
• Rapid wear reduces the commutator to its minimum
This commutator has been machined, emphasizing the
diameter more quickly. Commutator life may be
depth of the flat spots caused by a stall condition.
reduced by years.

Lubricant from the bearing coated the outboard portion of

this commutator, interfering with the film. Classic evidence of a stall.

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Section 11 — Failure Analysis Fundamentals of DC Operation and Repair Tips

BRUSH AND BRUSHHOLDER FAILURES

Flashover protection may be tabs (shown) or a ring. This

sacrificial part protects the commutator and brushholders.
Note the equalizer jumpers that ensure brush current is The coiled spring is less common for brushholders. The
shared equally. spring cannot be adjusted for the desired brush pressure.

Regardless of machine size, brush spacing around the

Constant-tension springs will uncurl if current weakens commutator must be consistent. The rule of thumb on
them. larger machines is spacing should be equal within 3/64”.

The stud insulators should be clean, slick and free of cracks that might trap carbon. These boxes pivot on a round post,
so uneven spacing above the commutator will also result in uneven spacing around the commutator circumference. Note
the constant-pressure springs.

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Fundamentals of DC Operation and Repair Tips Failure Analysis — Section 11

FIELD COIL, SERIES AND INTERPOLE FAILURES

These field coils are taped to seal out contamination. The

Coil insulation sometimes masks thermal damage. In-
tape also traps heat, making inspection difficult. When
spection may require careful removal of coil insulation.
any of the fields of a set is shorted, inspect the other fields
The tape can trap heat.
should be for evidence of thermal stress. Slit the tape and
look for discolored wire.

This interpole is potted to the pole iron and is positioned

away from the frame to increase airflow.

Potting the field coil to the laminated pole iron improves

heat transfer.

These interpoles exhibit obvious thermal stress. The

epoxy insulation is charred due to heat, probably caused
by excessive current through the interpoles. This could
result from overload, incorrect connection (wrong num-
ber of parallel circuits), restricted ventilation, or related
problems.
When interpoles show a marked difference in thermal
stress, parallel circuits might not be balanced. The cause
may be missing equalizer jumpers.

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Section 11 — Failure Analysis
COMPENSATING WINDING FAILURES
This type of compensating winding has multiple turns, so
turn-to-turn shorts are possible.
These compensating windings show signs of thermal
stress and deterioration of the insulation.
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Fundamentals of DC Operation and Repair Tips
Bracing separates the individual turns of the compensat-
ing winding. Contact between turns can result in dramatic
failures due to the high current involved.
These compensating winding jumpers are fully taped,
but are not physically braced to prevent contact. While
this design looks very rigid, blocking between the com-
pensating winding ends is recommended. Because of
the high current carried by the compensating winding
(equal to the armature current), a short between them
results in dramatic faults with extensive damage.
The connecting jumpers have been removed and the bar
ends cleaned to assure a good joint.