Chapter 3 - AutomationDirect
Contents
1. coils burned out or Correct short circuit This may require bringing the short circuiting motor to a repair shop Brushes not bearing down Check brush position and bearing pressure correctly Replace worn brushes Break in starter circuit Repair break Correct short circuit This may require bringing the Jerky starting Armature short circuit i motor to a repair shop Commutator short circuit Check commutator and repair short circuit Short circuit in the supply Locate short circuit and repair Motor will not run under load Overloading Check current input and remedy overload Voltage drop Increase supply line cross section Decrease IR compensation Controller Check speed potentiometer wiring and signal and repair if needed Motor overspeeding and hunting while under load Check voltage and current levels and correct Overloading A 5 overload condition Insufficient airflow Improve cooling conditions Motor overheating Cooling air temperature too high If TEFC model inspect the fan for damage Check windings and soldered connections Repair Armature winding short circuit is coils or windings IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 3 5 Chapter 3 Maintenance and Troubleshooting WVAUTOMATIONDIRECT ee eee Page 3 6 IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 20142. MAINTENANCE AND TROUBLESHOOTING TABLE OF CONTENTS Routine Maintenance 1 1 we ee a a a a a a n Bearing Size Information 1 0 1 0 en a a a a a e Replacing Brushes 6 6 6 oaoa a aa Troubleshooting 1 1 0 ee ne ns IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 3 1 Chapter 3 Maintenance and Troubleshooting VAUTOMATIONDIRECT OS ROUTINE MAINTENANCE A routine maintenance schedule should be developed for every IronHorse motor installation based on the individual application Motors installed in a harsh running environment should be serviced more frequently than those installed in a clean climate controlled area The following list should be used as a basis for creating the routine maintenance schedule 1 Clean the motor housing using a brush soft cloth or compressed air Remove any dirt and dust from the fan and fan cover vents 2 Frequently monitor the bearing temperature on the motor It should not exceed 60 C 140 F 3 Have the insulation checked periodically by an authorized motor specialist 4 Replace the motor brushes after every 2500 hours of operation BEARING SIZE INFORMATION Drive End Bearing SKF Opposite Drive End Frame Size Type Bearing SKF Type Small Frame not user serviceable 56C 6203 6203 All IronHorse 56C frame motors use premium sealed SKF brand bearings Page 3 2 IronHorse General Purpose DC Motors User Man
3. bing or rumbling noise from bearing Possible Causes Bearing is defective Solutions Replace bearing Whistling noise from bearing Bearing has run dry Replace bearing Faulty cage Replace bearing Excessive bearing wear Bearing overloaded Check alignment belt tension gear pressure coupling thrust Reduce bearing load If needed reduce additional axial load Scoring when motor is inoperative Bearing is being subjected to vibration from outside source Isolate motor from source of vibration or keep motor turning over Scoring when motor running Current leakage Remove motor from service Repair or replace motor Bearings in the small frame PMDC motors are not user replaceable replace motor instead of bearings IronHorse General Purpose DC Motors User Manual 2nd Edition 03 04 2014 VAUTOMATIONDIRECT Chapter 3 Maintenance and Troubleshooting S TROUBLESHOOTING CONTINUED Problem Possible Causes Solutions Motor shaft rotates in wrong direction should rotate clockwise when facing shaft Positive and negative input power leads are Switch the input power connections reversed Break in the armature supply Check and repair connection Fuse is blown Replace fuse Controller damaged or Check starter for break in circuit and repair break incorrectly connected Motor fails to start off load Armature
4. eral Purpose DC Motors User Manual 2nd Edition 03 04 2014 Page 3 3 Chapter 3 Maintenance and Troubleshooting TROUBLESHOOTING To prevent serious damage faults observed when a motor first goes into service or during subsequent operation should be investigated and repaired immediately These troubleshooting tables cover most common PMDC motor problems A Page 3 4 WARNING EQUIPMENT YOUR MOTOR WAUTOMATIONDIRECT TO PREVENT SERIOUS PERSONAL INJURY AND DAMAGE TO YOUR ALWAYS DISCONNECT INPUT POWER BEFORE INSPECTING OR REPAIRING Problem Possible Causes Solutions Motor vibrates or runs noisily when coupled up but runs okay when uncoupled Defective transmission components or problem with the machine being driven Inspect transmission and drive components Check alignment Foundation has become unlevel Realign machine set Check and repair foundation level Problem with gear drive Align drive check driving and driven gear pitch circles Incorrectly balanced drive or driven machine components Re balance drive and or driven components Motor runs rough when uncoupled Bearing damage See Bearing Problems troubleshooting table Mounting bolts are loose Re tighten and lock mounting bolts Fitted drive components coupling or pulleys affecting rotor balance Balance rotor with coupling or pulley fitted Problem Scratching rub
5. ual 2nd Edition 03 04 2014 VAUTOMATIONDIRECT Chapter 3 Maintenance and Troubleshooting REPLACING BRUSHES WARNING TO PREVENT SERIOUS PERSONAL INJURY AND DAMAGE TO YOUR EQUIPMENT ALWAYS DISCONNECT INPUT POWER BEFORE REPLACING BRUSHES A spare set of brushes ship in each 56C frame PMDC motor box and the brushes should be replaced after every 2500 hours of operation Small frame PMDC motor brushes should be replaced as needed If you visually inspect the brushes the minimum acceptable length is 6mm See Chapter 4 Accessories for replacement brush ordering information Make sure you install the correct replacement brushes check the part numbers carefully Ensure that the replacement brushes are the same width as the brushes being removed from the motor DO NOT install smaller brushes in a larger motor There is no break in period with new brushes Replacement brush and spring assembly sets es NOTE THE BRUSHES ARE SPRING LOADED BE CAREFUL WHEN REMOVING THE BRUSH COVER Motor has two brushes one on each side of the motor Always replace the brushes in pairs 1 Remove the brush cover using a flathead screwdriver as shown Turn the brush cover counterclockwise to remove 2 Carefully remove the old brush and spring assembly and install the replacement 3 Reinstall the brush cover turning clockwise 4 Replace the other motor brush and spring following the same steps IronHorse Gen
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