Repair Report (DC Motor)

Customer

Order
Number

Rockwell Automation

Job No

EA 052903

Description 250 Hp DC Motor

Make Reliance
Frame

C4414 ATZ

Model

12438101

Outgoing Photo

Power (Kw) 250 Hp

Speed (rpm) 850 / 2000
Voltage (v) 500 v Arm, 300 v Field
Current (A) 397 A, Arm, 18.83 A Field
Winding Shunt
Mounting Foot B3

Reported Faults / Customer Observations

Repeated failure of Drive End bearing
12 -13 months after servicing

Date

Nameplate

14 February 2010

60481

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

Tel - 01782 411021 web - www.fletchermoorland.co.uk

Inspection / Test Run

Test Run Conformance Check

Comments

High amplitude, high frequency vibration velocity and acceleration most noticeable at position 2 (drive
end) of the motor. Expectation of drive end bearing damage.

Incoming Photo

Stripdown report

The motor was relatively clean externally, internally there

was evidence of carbon dust contamination. A foot was
found to be broken on the resolver feedback module and a
louvred brushgear cover was damaged. The NDE bearing
was in good condition and the lubrication appeared clean.
The DE bearing was rough to turn by hand and the
lubrication appeared carburised. The NDE bearing housing
was oversize @ 170.035 mm.

Failure Photo

Failure Analysis

The DE bearing was removed, cleaned and dismantled. It

was evident from our failure analysis the bearing has
suffered electrical current discharge damage. Further
photos of the damaged bearing are shown later in this
report.

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

Tel - 01782 411021 web - www.fletchermoorland.co.uk

Mechanical Fits & Data

Journal Measurements - DE

Journal Measurements - NDE

Bearing 6219 C3

Bearing 6222 C3

Fit

Fit

Nominal 95

Nominal 110

mm

Up Tol 110.028 mm

Up Tol 95.018 mm
Lo Tol 95.003 mm

Lo Tol 110.010 mm
Shaft size 3.6248 "

Pass

Fail

8 Point Measurements

Keyway 0.845 "

Pass

Fail

110.012

110.012

Pass

Fail

110.012

110.012

Bearing Shoulder run-out Pass

Fail

110.012

110.012

110.012

110.012

Bearing Shoulder run-out Pass

Fail

8 Point Measurements
95.015

95.015

95.015

95.015

95.012

95.012

95.015

95.015

Pass

Fail

Shaft run-out 0.01 mm

Housing Measurements - NDE

Up Tol 170.025

Pass

Nominal size 200

Lo Tol 170.000

8 Point Measurements

170.020

170.020

200.015

200.015

170.020

170.020

200.015

200.015

170.020

170.020

200.015

200.015

170.020

170.020

200.015

200.015

Pass

Fail

Pass

Rotor Balance Data

Balance grade G1.0

G2.5

Balance grade to ISO 1940/1 : 2003 Part 1

Foot Flatness
0.05

0.00

Permitted (g)

Actual (g)

Position (Deg)

NDE

14.76

2.99

232

DE

14.76

10.80

52

0.05

No of Bars

0.05

Total Indicated
11
Run-out (TIR)

Motor viewed
from above

Fail

Plane

Commutator Profile

0.00

162

TIR Reading
Good > 50 um
Satisfactory > 75 um

microns (um)

Comments

0.00

0.00
0.00

mm

Lo Tol 200.000

Up Tol 200.028

8 Point Measurements

0.00

Fail

Housing Measurements - DEEE

mm

Nominal size 170

0.00

mm

0.00

NDE housing was oversize 170.035 mm on

inspection.

0.00

Tel - 01782 411021 web - www.fletchermoorland.co.uk

Commutator Profile
Commutator Profile (Blue trace- as received, Red trace- after machining)
P rofilr MAS - Com m u!a tor- Radi:a I
Plot

-1

v;0

40

-..!.

+
o]J

EO

<I)

;;:I

\-\.-

t:
}.:.
'

...-

\;,
\

-1

80

100

Fl:!cord ing

Pbt

Fl:!oo.:irg 1
Fl:!oo.:irg 1

-100

100

1
Rec;

Recording

s !9 rt

10 (1 0:52:37 am)
15 Jon 2J) 10 (12:07:18 prn)

2f; Jon 2fJ

-1

-100

Max BTB
tiJdQ SiLe
Ra.d:al TIR
Scale (+f.. 100 MiciD'ils)

( 1 2) 12 B<rs
( 187) 17 B<rs

11 IJnl :52-12
941-Jrn : 99-100

3 : 21-22
32:100.109

Mean BTB

Std V SUS Ct

HiMi::a

1D
4.4

02
4.7

0
1

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1 OG

Tel- 01782 411021 web- www.fletchermoorland.co.uk

0
0

Fl:!marK

Repair Details / Service Report

The motor was fully stripped down and all mechanical parts were checked for correct fit and tolerance.
The NDE bearing housing was found to be oversize 170.035 mm (Tolerance 170.025mm - 170.000mm)
The housing was bored, sleeved and machined to 170.020 mm. All mechanical parts were blast
cleaned and all interior surfaces were spray painted with an anti-track paint. The windings were cleaned
and checked for integrity. All winding temperature control devices were checked for correct function.The
commutator was profiled before being skimmed, undercut and chamfered. A finished profile was
recorded. The armature was dual plane dynamically balanced to an enhanced G1.0 balance grade for
low vibration operation. The resolver feedback module was checked for correct function and outputs
(2,2v pk vector, 2,2v pk SIN, 2,2 vpk COS) Mechanical repairs were carried out to the resolver foot and
louvred brushgear panels. A genuine SKF insulated bearing was fitted to the NDE of the motor (6219
C3 VL0241) A SKF 6222 C3 was fitted to the DE.
The motor was assembled and 16 pairs of new brushed were fitted and bedded in.
The motor was run on our test bed and SKF conformance check results were taken and recorded.
The motor was spray painted and packaged ready for delivery.

Electrical Data - Static Test

Insulation
Resistance (IR)
Winding
Resistance
Earth leakage

Field Circuit
999
MOhm @
Ohms

Winding
Resistance

0.013 0.014

Earth leakage

7.62

500

15.1

uA @

3.42

Armature Circuit
999
500

Insulation
Resistance (IR)

1800

Electrical Data - Run Test

Ohms
uA @

1800

Load test

No load test

Voltage - Armature

356

Voltage - Armature

Current - Armature

14.6

Current - Armature

Voltage - Fields

50

Voltage - Fields

Current - Fields

4.3

Current - Fields

Motor Speed

rpm

Measured Output Power

Kw

Motor Speed

1485

rpm (CW)

Motor Speed

1486

rpm (CCW)

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

Tel - 01782 411021 web - www.fletchermoorland.co.uk

MOhm @

Measured Output Torque

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

Tel - 01782 411021 web - www.fletchermoorland.co.uk

Nm

Mechanical Conformance Check Data & Vibration Analysis

Conformance Check

Vibration Analysis

Comments

The final test run show the motor has passed the SKF conformance check. Compared to the initial test
run all vibration levels are within limits for each band.
This motor has been fitted with an insulated bearing fitted on the NDE of the motor. Do not allow any
ground connection to be made to this bearing by fitting temperature sensing or other metallic
conductors.

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

Tel - 01782 411021 web - www.fletchermoorland.co.uk

Further Analysis / Information

Photo

Description

Evidence of carbonisation of lubricant as found on

stripdown, note the fresh lubricant evident on the outer
race of the bearing. (this has not entered the bearing
and has not been subjected to electrical current
discharge.

Photo

Description

Frosting evident on the inner raceway of the bearing.

Photo

Description

fluting evident on the outer raceway of the bearing.

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

Tel - 01782 411021 web - www.fletchermoorland.co.uk