New Baldor Spindle Drives, new for less money than most repaired and even comes with 2 Year Warranty. In fact, early this year, it was announced in the news by the President of the Philippines that there will be more POEA jobs for Canada. This will number up to about. What is the rewind scenario if a motor fails? What is the rewind scenario if a motor fails? Increasing Motor Efficency. · Hello. Does anybody know how to find the correct 'pairs' of leads for a induction motor that is connected in a double wye configuration with the two wyes comple.Unlike an initial motor purchase where your decision is limited to procuring a standard versus a premium efficiency motor, a motor failure or burnout produces three alternatives. Your options are to rewind the failed motor, purchase a new standard- efficiency motor, or purchase an energy- efficient replacement motor. For this scenario, motor installation labor costs are again not included as the existing motor must be removed and reinstalled anyway. ![]() HP Emergency Motor Rewind – Seized motor under repair. Assuming that the failed motor can be rewound, the baseline or lowest initial cost approach is to rewind the motor to its original specifications. As some older U- Frame motors were built with oversized slots, it is sometimes possible to perform a “high- efficiency” rewind and slightly increase the efficiency of the motor by adding more copper to reduce I2. R losses. If the original unit was wound with aluminum wire, it should be replaced with copper. A motor should be rewound with the same (or larger) winding wire size and configuration. If a repair shop does not have the correct wire size in stock and uses a smaller diameter wire, stator I2. R losses will increase. While a decrease in the number of turns in a stator winding reduces the winding resistance, it also shifts the point at which the motor’s peak efficiency occurs toward higher loads and increases the motor’s mag- netic field, starting current, locked rotor, and maximum torque. A change from 1. In a typical rewind, the stator is heated to a temperature high enough to bum out its winding insulation. The windings are then removed and replaced. In the past, many rewind shops emphasized speed High temperatures were used to shorten repair times and get the motor back in service quickly. Hand- held torches were sometimes used to soften varnish for easier coil removal. The resulting higher temperatures increase losses by changing the electrical characteristics of the motor’s core. For both standard and high- efficiency motors, the rewind shop should follow the motor manufacturers’ rec- ommended burnout temperature specifications. When stripping out the old windings, it is essential to keep the stator core below 7. F. If the stator core gets too hot, the insulation between the stator laminations will break down, increasing eddy current losses and lowering the motor’s operating efficiency. After being damaged, the lamination insulation cannot be repaired nor the efficiency loss restored without under going a major repair such as restacking the iron. The motor also becomes less reliable. Insulation removal techniques vary between rewind shops and should be investigated prior to deciding where to have the motor rewound. ![]() ![]() Always choose a shop with a controlled temperature winding burnout oven to minimize core loss. Some shops have core loss testers and can screen motors determine if they are repairable prior to stripping. The repair shop should also determine and eliminate the cause for a motor’s failure. Aside from proper strip- ping procedures, the motor owner should ensure that the rewind shop does the following: Uses proper methods of cleaning. Installs Class F or better insulation. Uses phase insulation between all phase junctions. Uses tie and blocking methods to ensure mechanical stability. Brazes rather than crimps connections. Uses proper lead wire and connection lugs. Applies a proper varnish treatment. As motor design characteristics (such as slot geometry and configuration), failure modes, rewind practices, and materials specifications and treatments vary, it is impossible to identify a “typical” rewind cost for a motor with a given horsepower, speed, and enclosure. Motor efficiency losses after rewinds also vary considerably. While dynamometer tests conducted by the Electrical Apparatus Service Association indicate that new motors, when properly stripped and rewound, can be restored to their original efficiency, field tests on motors from a variety of manufacturing plants indicate that losses are typically higher in motors that have been rewound- perhaps because of thermal shock suffered during the motor failure. An analysis of core loss tests taken over a 1 year period in General Electric repair facilities indicates that average core losses are 3. General Electric also conducted a test of 2. The test indicates that total losses increased by 1. An 1. 8 percent increase in losses corresponds to an approximate 1. Rewound motors can exhibit severe efficiency losses, especially if they were rewound more than 1. Rewind losses of 5 percent or more are possible. When should a energy- efficient motor be purchased in lieu of rewinding a failed standard- efficiency motor? This decision is quite complicated as it depends on such variables as the rewind cost, expected rewind loss, energy- efficient motor purchase price, motor horse- power and efficiency, load factor, annual operating hours, electricity price, and simple payback criteria. At least some of the time, rewinding will be the best decision. The prospects for a good rewind are greatly im- proved if you keep good records on your motors and provide them to the repair shop. Repair shops often can’t get complete specifications from manufacturers. They must “reverse engineer” motors, counting winding turns, noting slot patterns, measuring wire size, etc. Sometimes a motor has failed repeatedly in the past because of a previous non- standard rewind. The same error can be repeated unless the shop knows the motor is a “repeat offender” and di- agnoses the problem. Similarly, a motor is sometimes subjected to unusual service requirements, e. Most shops know how to modify original specifications to adjust to such conditions. Rules Of Thumb. Here are several rewind “rules of thumb”: Always use a qualified rewind shop. A quality rewind can maintain original motor efficiency. However, if a motor core has been damaged or the rewind shop is careless, significant losses can occur. Motors less than 1. It is usually best to replace them. If the rewind cost exceeds 6. In- creased reliability and efficiency should quickly recover the price premium. If your energy costs average $0. Wh or more, and a motor is operated for at least 4,0. The higher purchase price will usually be repaid through energy savings within 2 years. Here is a chart to help decide when to select an energy efficient motor: Choose a new energy- efficient motor if: Your energy costs are: Annual hours of use equals or exceeds: $0. Wh. 6,0. 00$0. 0. Wh. 4,0. 00$0. 0. Wh. 3,0. 00$0. 0. Wh. 2,0. 00. Table 1 indicates how breakeven rewind costs vary with respect to motor operating hours and simple payback criteria. The breakeven cost is expressed as a percentage of a replacement energy- efficient motor price. A new energy- efficient motor should be purchased if the rewind cost exceeds the stated breakeven point. Table 1 may be used for NEMA Design B motors in the 5- to 1. Assumptions used in the preparation of this table include an expected 2 percent loss in an average standard motor efficiency due to rewinding, replacement with an average energy- efficient motor operated at a 7. Table 1 – Breakeven Rewind Cost as a Percentage of an Energy- Efficient Motor Price. Simple Payback Criteria (Years)Annual Operating Hours. You can easily complete a cost- effectiveness analysis for a rewinding. If you can be assured that the past and prospective rewinds comply with all the foregoing recommended practices, the original efficiency could be maintained. Otherwise, two points should be subtracted from your standard motor efficiency to reflect expected rewind losses. Annual energy and cost savings are determined by inputting the appropriate energy- efficient motor performance, operating hours, electricity price, and load factor into Equations below. The incremental cost of procuring the premium- efficiency unit is the quoted price for the new motor less the rewind price and any utility rebate. Where: hp = Motor nameplate rating. L = Load factor or percentage of full operating load. Estd = Standard motor efficiency under actual load conditions. EHE = Energy- efficient motor efficiency under actual load conditions as. The simple payback for the energy- efficient motor is simply the incremental cost divided by the total annual energy conservation benefits. Motor Rewinding Process (VIDEO)Reference: Energy- Efficient Electric Motor Selection Handbook – Gilbert A.
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