VonRoll - 5.2 LV Failure Analysis KBA

Introduction to Low Voltage
Failure Analysis
Kevin Alewine
19 June 2008
LV Materials and Applications Training

1 | Date | Event, Location | Presentation title
Credits
Thanks to the following

g for their contributions and criticisms:
Hal Miller, Von Roll USA

Dr. Nancy Frost, Von Roll USA
Geoff McEwan, Toshiba International
Joe Sedberry, Grayson Armature Works
Pat Bump, Shermco Industries
Other references
US D
Dept.
t off E
Energy Offi
Office off Industrial
I d t i l Technologies,
T h l i
M t Repair
Motor
R
i
Tech Brief, 2000
Melfi, Snug Bell, Skibinski, Effect of Surge Voltage Risetime on the
Insulation of Low Voltage
g Machines Fed by
y PWM Converters, IEEE
1997
Fenger, Campbell, Pederson, Dealing with Motor Winding Problems
Caused by Inverter Drives, IEEE 2003
Electrical Apparatus Service Association
Association, Root Cause Failure
Analysis, 2002-2004
2 |19June2008 |VonRollUniversity,Meyzieu,France|IntroductiontoLowVoltageFailureAnalysis
Why this overview?

How do materials and design influence performance
and failures?
How to interpret cadaver evidence
Traditional failures vs
vs. VFD failures
What is low voltage?

<1000VAC
Non-mica insulated
Normally random wound designs
Insulation is by far the most

i
important
t t problem
bl
in
i electrical
l ti l
design
Charles P. Steinmetz
How do materials influence performance?
El t i l
Electrical
Mechanical
Expected
Performance
Thermal
Chemical
How about design?
Design
Thermal rise
Electrical
Load
L d
Ventilation
Adequate wire size
Mechanical support
Bracing
Wedges
Adequate insulation
Voltage
Mechanical
M h i l
How about workmanship?
Stator core alignment

Smooth laminations
Proper consolidation
Slot
S liner/wedges
/
No tears or cracks
Good fill of slot
Resin
Adequate fill
Proper
P
cure
How about workmanship?
Winding
Not damaged during looping

Wires properly aligned
N t dropped
Not
d
d behind
b hi d iinsulation
l ti
Not damaged during insertion
Not damaged during forming
Good connections
Good resin fill and retention
Good resin bond strength at operating temperature
Especially important in VFD applications!
Common materials in LV motors
Magnet
g
wire
MW-35 standard enamel
Corona resistant
Slot liners/phase
Discrete materials
PET film
Rag
Nomex
Laminates
RM
DMD
NMN
Coated materials
Wedges/internal
g
p
phase/fillers
Discrete materials
Laminates
Connections
Sleeving
Tapes
Support
Tapes
Tie cords
Surge support
Resin/Varnish
Specialty coatings
Types of windings
Random mush wound

Several round wires, isolated by circuit, but not by turn
Fast and easy
Varying
V i d
degrees off tturn to
t turn
t
stress
t
potential
t ti l
dependent on chance orientation
Most common design
Oriented random wound

Basically the same but with careful orientation of wires
typically
yp
y machine wound
Avoid first turn placement near later turns
Additional insulation on first turn in extreme designs
Types of windings
Form wound designs

Typical in larger LV generators
Mica or non-mica insulation
Careful orientation of strands
Mechanically robust design
Higher slot fill for improved efficiencies
Root cause failure examples
Design/materials/
workmanship issues
Insulation
Dielectric aging
Tracking on
surface
Core loss
Heat
Ambient temperature
Reduced air flow
Frequent starts
Humidityy
Loadconditions
Misapplication
Misalignment
Vibration
Stalls
Loadcycling
Condensation at
idle
Contamination
Ab
Abrasion
i
Chemical attack
Rotordrag
Animal attack
Rodent
Insect
Power supply issues

Imbalance
Surges
VFD issues
Impulses
Transient currents
Bearingfailure
Unbalancedrotor
Rotorbarfailures
Typical failure path
Movement of wire within coil structure

Turn to turn failure
Increased heat
Leakage through insulation

Additional heat and destructive corrosion
Catastrophic failure to ground
Types of failures - Shorts
Turn to turn ((strand insulation

failure)
Some root causes
Faultyy insulation
Coil movement
Vibration
Over voltage
g conditions
VFD voltage spikes
Appearance
Signs
g of heat degradation
g
to insulation
Often leads to phase or
ground failure, especially if
i th
in
the slot
l t section
ti
Phase failure
Similar causes as turn to
turn
Appearance
Insulation burning
between two phases
Can be in the slot or on
the overhangs
Leads to more rapid
failures
Shorted connection
Appearance
Burning at lead
connection
ti point
i t
Typically to another phase
Can be insulation failure
due to high resistance
connection creating
excess heat
Ground failures
Typically in or near slot
section
Often features molten or
vaporized copper
Many different causes
Often
Oft the
th fatal
f t l failure
f il
regardless of root cause
Shorted coil
Edge failure
Types of failures Power supply issues
Unbalanced
Unbalanced
Voltage
Voltage Surge
Types of failures Power supply issues
Single
Single Wye (Star)
Single
Si l Delta
D lt
Types of failures Load issues
Overload
Overload
Locked
L k d rotor
t
Types of failures Load issues

Overall degradation of insulation is normally an
overload
l d or misapplication
i
li ti off th
the motor
t
A lack of pattern normally represents insulation failure
Incorrect materials
Defective
Incomplete cure
E t
External
l causes as outlined
tli d previously
i
l
Types of failures Moisture, corrosion
VFD Failures
Variable Frequency Drives

Most common is IGBT (Insulated Gate Bipolar Transistor)
Repetitive voltage stress, in both magnitude and risetimes,
often exceeds the dielectric strength of the insulation
NEMA MG-1 Part 31 specifies 1,600 volt spike with a 0.1
microsecond risetime
Some
S
drives
di
ffor motors
t
can produce
d
pulse
l voltages
lt
th
thatt
exceed 2500 volts
VFD Failures
VFD Failures
Variable Frequency Drives

Corona
Ionization of air
Visible
Vi ibl and
d audible
dibl att certain
t i ranges
Cause destructive corrosion of organic materials
CIV corona inception voltage
Voltage where corona begins in an insulation system
CEV corona extinction voltage

Voltage where corona, once it is started, will stop
VFD Failures
Motors designed without adequate phase to phase

insulation will exhibit rapid breakdown due to these
voltage spikes.
T
Typically
i ll phase
h
tto phase
h
ffailures
il
Location determines whether they resemble dead shorts or
phase imbalance
VFD Failures
With proper phase insulation, breakdown commonly

occurs in the end turns.
Partial discharge erosion of the insulation
Often
Oft appears as coilil to
t coilil shorts
h t with
ith characteristic
h
t i ti
degradation of the magnet wire insulation
Normally occur at highest stress points where first turns of
th liline coilil tto th
the
the llastt tturns off th
the oilil group
Conclusions
Conclusions
Materials, design, environment and workmanship all

influence not only overall insulation life, but the type of
failures.
All off the circumstances off a motors
application must
be known and understood before accurate analysis of
the failure.
Sometimes, the destruction is enough to mask the
true electrical root cause of the failure.
Root cause must be determined by reviewing other
factors including mechanical causes.

VonRoll - 5.2 LV Failure Analysis KBA

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Introduction to Low Voltage

LV Materials and Applications Training

Thanks to the following

Hal Miller, Von Roll USA

Why this overview?

What is low voltage?

Insulation is by far the most

How do materials influence performance?

How about design?

How about workmanship?

Stator core alignment

How about workmanship?

Not damaged during looping

Especially important in VFD applications!

Common materials in LV motors

Random mush wound

Oriented random wound

Form wound designs

Root cause failure examples

Power supply issues

Typical failure path

Movement of wire within coil structure

Leakage through insulation

Catastrophic failure to ground

Types of failures - Shorts

Turn to turn ((strand insulation

Types of failures - Shorts

Types of failures - Shorts

Types of failures - Shorts

Types of failures - Shorts

Types of failures Power supply issues

Types of failures Power supply issues

Types of failures Load issues

Types of failures Load issues

Types of failures Moisture, corrosion

Variable Frequency Drives

Variable Frequency Drives

CEV corona extinction voltage

Motors designed without adequate phase to phase

With proper phase insulation, breakdown commonly

Materials, design, environment and workmanship all

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