HOW TO TROUBLESHOOT

MOTORS & DRIVES

>>
Taking measurements, starting at the inputs, can ensure a motor and
drive system is getting the high-quality power it needs, and that its not
adversely affecting power quality upstream.
Its important to look closely at the rst segment in a three-phase motor and
drive system from the mains supply at the drive input to the drive itself. Tese
measurements will help identify common problems. Also, knowing what tools to
use for a given situation and how to apply them will enable more quick and accurate
troubleshooting.
Te test points in a typical three-phase motor drive system (see Figure 1) include:
Te drive input where AC power enters the drive from the mains.
Te drive and its output, where the AC to DC converter, the DC nlter, and the
DC to AC inverter provide the three-phase power to the motor.
Te motor and drive train itself.
Follow these steps to learn about troubleshooting tools and
how to use them for problems in a typical three-phase motor
and drive system, from the inputs to the drive.
By Hilton Hammond, Product Manager, Fluke Corp.
33 WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL DECEMBER 2012 | THE JOURNAL
AC to DC
Conversion
Mains
Supply
Mechanical
Output
Motor (Load) Cable
Interface
DC to AC Converter DC Filter
and Buffer
bus
voltage
L1
T3
PWM Output
L2
T2
L3
Gnd
T1
+Vdc
-Vdc
T3
T2
T1
DRIVE
INPUT MOTOR AND DRIVE TRAIN DRIVE AND DRIVE OUTPUT
PROBLEMS
Nominal Supply
Voltage
Voltage Unbalance
Transients
Harmonic
Power Factor
Voltage Unbalance
Current Unbalence
Sigma Current and PE Current
Control Signal
Output Transients
Distrurbances
Harmonics
Volt to Hertz Radtio
Diagnostic Shutdown
Motor Overload
Single Phasing
Bearing Failures
Misalignment
Imbalance
Looseness
Insulation Breakdown
Shaft Voltage and
Bearing Current
Figure 1. This graph illustrates a three-phase motor and drive system and common problems.
34 THE JOURNAL | DECEMBER 2012 WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
Introduction to Input Measurements
When troubleshooting a motor and drive system, checking
the supply voltage, current and frequency rst can rule out
problems that might aect performance. Tis saves time and
leads to faster problem resolution. In addition, identifying
over- or under-voltage conditions can avoid nuisance tripping
of drive fault circuits and eventual motor-drive damage.
Input measurements can be taken at a number of loca-
tions. Figure 2 shows dierent input points going from the
main service entrance to subpanel or disconnect switch to the
power input at the drive.
Potentially, each of these points could provide dierent
results if theyre aected by other loads on the circuits.
Input measurements should be taken to:
Determine if there's enough capacity to power the motor
and drive system.
Establish power quality.
Make sure the drive load isn't adversely anecting power
quality in the system, such as a motor drive generating
harmonics or creating dips that could disrupt operations.
Te voltage, current and frequency of the electricity power-
ing a variable speed motor system can aect both its short-
term and long-term operation, so its best to start diagnostics
at the input side.
Three Primary Measurements
Nominal supply voltage, current and frequency are the
primary measurements for voltage supplied to the drive under
normal operating conditions. Nominal voltage is the named
(or rated) voltage at which the device is designed to operate.
Nominal values provide a basis to compare measurements.
Starting at the input of the motor drive, measure voltage,
current and frequency, then compare your measurements
with nominal values.
You can take measurements with a digital multimeter
and a current clamp, just as you would on a single-phase
circuit, but a three-phase power quality analyzer makes
the job easier (see Figure 3). Measuring three phases
simultaneously can reveal interactions between phases that
cant be seen with single-phase measurements. When mea-
suring, be sure the power quality analyzer is connected to
the correct circuit type.
Te amount of deviation from nominal thats considered
acceptable varies by locale, but as a rule:
Voltage should be within 10% of nominal.
Current should never exceed the load's nameplate rating.
Frequency should be within 0.5 Hz of nominal.
Evaluating Measurements
A measurement of more than 10% out of range means there's
potentially a supply voltage problem. For long-term trouble-
shooting, attach a power quality analyzer. If the voltage is
consistently too high, consult with the electric utility.
If voltage is too low, check whether the local circuit is over-
loaded by comparing current measurements with the circuit
breaker rating. If the measured current is within the range of
the breaker, check the size of the cable that supplies the drive
to make sure it conforms to National Electric Code (NEC)
requirements.
If voltage measurements are within an acceptable range
and the circuit appears to be correctly congured, but there
are still problems (such as the motor drive resetting or circuit
breakers opening), intermittent power supply problems might
be present. To detect problems happening over a longer time
Main Switchgear
Disconnect
Switch
Motor Drive
Motor Load
L1
L2
L3
T1
T2
T3
L1
L2
L3
Figure 2. Input points go from the main service entrance, to subpanel or disconnect switch, to the power input at the drive.
35 WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL DECEMBER 2012 | THE JOURNAL
or until the next fault occurs, use a power quality analyzer or
power quality recorder to log any disturbances on the circuit.
If all voltage, current and frequency measurements are within
an acceptable range, check for voltage and current unbalance.
Voltage and Current Unbalance
Ideally, voltage and current measured in each phase of a three-
phase system should be the same. Because voltage or current
unbalance can cause downtime or damage to a motor drive,
its important to know how to interpret these measurements.
Expressing the amount of voltage or current unbalance as
a percentage helps determine the size of the problem quickly
with a single number. To get the percentage of unbalance,
divide the biggest deviation measured on one phase by the
average of three phases and multiply by 100.
For example, if you measured 480V, 485V and 490V,
the average voltage is 485 and the biggest deviation is 5V.
Five volts divided by 485V is .01, which gives a 1% voltage
unbalance when multiplied by 100.
480V+485V+490V
3 = 485 average voltage
5V maximum
deviation from average
485V average *100 = 1% voltage unbalance
As little as a 2% voltage unbalance can cause voltage
notching and excessive current ow in one or more phases
going to the motor. Voltage unbalance can also cause tripping
of the motor drives current overload fault protection.
Current unbalance is a measure of dierence in current
drawn on each leg of a three-phase system. It can cause over-
heating and deterioration of motor-winding insulation.
Te draw on each leg should be equal or close to equal.
Voltage unbalance can cause current unbalance far out of
proportion to the voltage unbalance itself. When current un-
balance occurs in the absence of voltage unbalance, look for
another cause of the unbalance; for example, faulty insulation
or a phase shorted to ground.
Just like voltage unbalance, current unbalance is calculated
as 100 times the maximum current variation from average,
divided by the average current of the three phases. So, if mea-
sured current is 30A, 35A and 30A, the average is 31.7A, and
the current unbalance is: [(35 31.7) 100] 31.7 = 10.4%.
Current unbalance for three-phase motors shouldnt
exceed 10%. High neutral current can indicate unbalance.
Unbalance current will ow in neutral conductors in three-
phase wye systems.
Harmonics
Te 50 or 60 Hz frequency of the voltage supplied is called
the fundamental frequency. In a perfect world, the funda-
mental frequency is the only one present. Unfortunately,
some electrical loads (such as computers, controls, drives and
energy-saving lighting systems) can cause other frequencies,
called harmonics, to appear in measurements.
Most harmonic-generating devices can be found inside a
facility. Although motor drives can be aected by harmonics,
often theyre the source of harmonics aecting other devices.
If signicant levels of harmonics appear in drive measure-
ments, consider adding ltering to block those harmonics.
Transients
Transients are brief events (less than one half cycle, so less
than 1/120th of a second in a 60 Hz system) on the AC line.
Main Switchgear
Disconnect
Switch
Motor Drive
L1
L2
L3
T1
T2
T3
L1
L2
L3
L1 L2 L3
L1
L2
L3
Figure 3. Use a power quality analyzer connected to the drive input to measure the input side of the drive. Then, if needed, measure at the service entrance.
36 THE JOURNAL | DECEMBER 2012 WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
Many people associate transients with external events, such
as lightning surges, but transients can also originate within a
system or building. Detecting, troubleshooting and address-
ing transients is important because they can damage motors
and its circuitry.
Troubleshooting transients typically requires using a test
tool with a fault capture rate, such as a power quality ana-
lyzer or a portable oscilloscope.
Diagnostic Benets
Checking the primary measurements rst often can rule out
issues that might aect the motor drive or breaker circuits.
Diagnosing from the inputs can save time, lead to faster prob-
lem resolution and help prevent damage to the drive itself.
Editors Note: Testing from the inputs is one of many ways to
troubleshoot motors and drives. To learn more on testing from
the outputs, please see How to Measure Output Voltage from a
VFD to a Motor, in our April edition at http://bit.ly/H7iyEW.
Fluke Corp. is a participating Encompass Product Partner
in the Rockwell Automation PartnerNetwork. Based in Ever-
ett, Wash., Fluke Corp. manufactures, distributes and services
electronic test tools.
Fluke Corp.
www.rockwellautomation.com/go/p-uke
>> Review of the Fundamentals
Voltage: The amount of electromotive force being
applied to the system. Voltage is often compared to the
water pressure in a pipe.
Current: The amount of electrons flowing through
the wires. Electric current is often compared to the
volume of water flowing through a pipe.
Frequency: The number of times alternating current
(AC) changes direction. This frequency is determined
by the movement of magnets in the generator. Different
countries use electricity with different frequencies. In
the U.S. and Canada, the frequency is nominally 60
cycles per second (60 Hz). In most other countries the
frequency is 50 Hz.