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Features and Causes of Motor Overload Fault

2024-07-18

Latest company news about Features and Causes of Motor Overload Fault

    Motor overload fault refers to a condition where the current borne by the motor during operation exceeds its designed rated value, leading to overheating, damage, or shutdown of the motor. The following are some of the features and possible causes of motor overload fault:

 

latest company news about Features and Causes of Motor Overload Fault  0    

 

Features:

    1. Overheating: The motor's surface temperature rises abnormally, and there may even be a burning smell.

    2. Current Exceedance: The motor's operating current exceeds its rated current.

    3. Reduced Speed: The motor's speed decreases, and in severe cases, it may stop rotating.

    4. Abnormal Sounds and Vibrations: The motor produces low, rumbling sounds and vibrations during operation.

    5. Burning Smell and Black Smoke: In severe overload conditions, a burning smell may permeate the area around the motor, accompanied by black smoke.

    6. Winding Damage: The insulation part of the winding turns black and becomes brittle, and in severe cases, the insulation layer may carbonize into a powdery state.

 

Causes Analysis:

    1. Excessive Load: The actual operating power of the motor exceeds its rated power, causing overload.

    2. Open-phase Operation: One or more phases of the motor's three-phase power supply are missing, resulting in unbalanced motor operation.

    3. Voltage Issues: Operating voltage exceeding the allowable range of the rated voltage causes the motor winding to overheat.

    4. Mechanical Faults: Issues such as bearing damage or mechanical jamming can lead to decreased or stopped motor speed.

    5. Misoperation During Testing: For example, excessive duration of the locked-rotor test or insufficient capacity of the test equipment can cause the motor winding to overheat.

    6. Wiring Errors: Connecting a star-connected motor incorrectly in a delta configuration, or applying excessively high voltage during testing for motors with different frequencies and voltages.

    7. Power Supply Issues: The supply voltage being too high or too low causes the winding to overheat.

    8. Impact Load: Sudden increases in load can lead to a sudden decrease in motor speed.

    9. Bearing System Failure: Damaged bearings or seizure (where the rotor and stator come into contact) can cause motor overload.

 

Fault Diagnosis Methods:

    1. Check the Load: Confirm whether the motor is correctly selected and matched with the load.

    2. Measure Current: Use an ammeter or clamp-on meter to measure the motor's actual power consumption and compare it with the rated  value on the nameplate.

    3. Check Protective Devices: Verify that the motor starter's protective devices are correctly installed and adjusted.

    4. Clean Ventilation Openings: Regularly clean the motor's surface and ventilation openings to remove debris that hinders airflow.

    5. Check Motor Wiring: Ensure that the motor's wiring is correct and free from errors.

    6. Check Power Supply: Ensure that the supply voltage is stable and within the allowable range.

 

    Through the above features and cause analysis, motor overload faults can be effectively identified and addressed to ensure the safe and stable operation of the motor.

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