Protecting Motors Against Drive-Induced Damage San Jose CA

Damage To Bearings

Due to the high-speed switching frequencies used in PWM inverters, all variable frequency drives induce shaft current in AC motors. The switching frequencies of insulated-gate bipolar transistors (IGBT) used in these drives produce voltages on the motor shaft during normal operation through electromagnetic induction. These voltages, which can register 70 volts or more (peak-to-peak), are easily measured by touching an oscilloscope probe to the shaft while the motor is running.

Once these voltages reach a level sufficient to overcome the dielectric properties of the grease in the bearings, they discharge along the path of least resistance?typically the motor bearings?to the motor housing. (Bearings are designed to operate with a very thin layer of oil between the rotating ball and the bearing race.) During virtually every VFD cycle, induced shaft voltage discharges from the motor shaft to the frame via the bearings, leaving a small fusion crater in the bearing race. These discharges are so frequent that before long the entire bearing race becomes marked with countless pits known as frosting. As damage continues, the frosting increases, eventually leading to noisy bearings and bearing failure. A phenomenon known as fluting may occur as well, producing washboard-like ridges across the frosted bearing race. Fluting can cause excessive noise and vibration that, in HVAC systems, is magnified and transmitted by the ducting. Regardless of the type of bearing or race damage that occurs, the resulting motor failure often costs many thousands or even tens of thousands of dollars in downtime and lost production.

Failure Rates

Failure rates vary widely depending on many factors, but evidence suggests that a significant portion of failures occur only three to 12 months after system startup. Because many of today's AC motors have sealed bearings to keep out dirt and other contaminants, electrical damage has become the most common cause of bearing failure in AC motors with VFDs. If half of all AC motor failures are due to bearing failure, almost 80% of these are caused by electrical damage to bearings.

Mitigating Damage

As demonstrated above, electrical damage to VFD/AC motor bearings begins at startup and grows progressively worse. As a result of this damage, the bearings eventually fail. To prevent such damage in the first place, the induced shaft current must be diverted from the bearings by insulation or an alternate path to ground.

Insulation. Insulating motor bearings is a solution that tends to shift the problem elsewhere as shaft current looks for another path to ground. Sometimes, because of the capacitive effect of the ceramic insulation, high-frequency VFD-induced currents actually pass through the insulating layer and cause bearing failure. If attached equipment, such as a pump, provides this path, the other equipment often winds up with bearing damage of its own. Insulation and other bearing-isolation strategies can be costly to implement.

Alternate discharge paths. When properly implemented, these strategies are preferable to insulation because they neutralize shaft current. Techniques range in cost and sometimes can only be applied selectively, depending on motor size or application. The ideal solution would provide a very-low-resistance path from shaft to frame, would be low-cost, and could be broadly applied across all VFD/AC motor applications, affording the greatest degree of bearing protection and maximum return on investment.

Although there are a number of technologies now available to protect AC motor bearings from damage due to shaft currents, including the following:

Faraday shield. The shield prevents the VFD current from being induced onto the shaft by effectively blocking it with a capacitive barrier between the stator and rotor. However, this solution is extremely difficult to implement, very expensive, and has been generally abandoned as a practical solution.

Insulated bearings. Insulating material, usually a non-conductive resin or ceramic layer, isolates the bearings and prevents shaft current from discharging through them to the frame. This forces current to seek another path to ground, such as through an attached pump or tachometer or even the load. Due to the high cost of insulating the bearing journals, this solution is generally limited to larger-sized NEMA motors.

Sometimes, high-frequency VFD-induced currents actually pass through the insulating layer and cause bearing damage anyway. Another drawback is the potential for contaminated insulation, which can, over time, establish a current path through the bearings.

Ceramic bearings. The use of nonconductive ceramic balls prevents the discharge of shaft current through this type of bearing. As with other isolation measures, shaft current will seek an alternate path to ground. This technology is very costly, and in most cases motors with ceramic bearings must be special ordered and have long lead times. In addition, because ceramic bearings and steel bearings differ in compressive strength, ceramic bearings must be re-sized in most cases to handle mechanical static and dynamic loadings.

Conductive grease. In theory, because this grease contains conductive particles, it would provide a lower-impedance path through the bearing and would bleed off shaft current through the bearing without the damaging discharge. Unfortunately, the conductive particles in these lubricants increase mechanical wear to the bearing, rendering the lubricants ineffective and often causing premature failures. This method has been widely abandoned as a viable solution to bearing currents.

Grounding brush. A metal brush contacting the motor shaft is a more practical and economical way to provide a low-impedance path to ground, especially for larger NEMA-frame motors. However, these brushes pose several problems of their own: