A well-planned preventive maintenance program is the key to dependable, long-life

operation of motors and generators.

In modern plant operations, unscheduled stoppage of production or long repair shutdowns
are intolerable. The high cost of the resultant downtime eats deeply into profits. Although
management probably realizes the value of a good preventive maintenance (PM) program,
they sometimes resist the investment in proper tools, instruments, practices, or technical
assistance. Therefore, it's very important that you show how a properly planned
motor/generator PM program is justified.
Finally, select the best motor-maintenance techniques. For each type of motor, controller, or
related equipment, a variety of maintenance methods may be selected. Choose the best
methods and determine to what extent they should be applied. For example, should you
check for possible bearing trouble on a motor simply by feeling components for over
temperature and listening for unusual sounds, or should you install temperature monitoring
devices and make inspections using a stethoscope or an infrared scanner?
Basic guidelines to motor maintenance
Here are some valuable guidelines that you can use in your PM program.
Lubrication. Lubricate regularly according to manufacturer's instructions. On sleevebearing and other oil-lubricated machines, check oil reservoirs on a regular basis. In poor
environments, change oil at least once a month. Never over-lubricate; excess grease or oil
can get into windings and deteriorate insulation. Be sure to use only the lubricant specified
for the machine in question. However, you should also check into the possibility of using
modern lubricants that have excellent life and lubricating qualities.
Bearing inspection. Bearing failures are one of the most common causes of motor failures.
Typical bearing problems include improper lubrication, misalignment of the motor with the
load, replacement with the wrong type bearing, excessive loading, and harsh environments.
On essential motors or those that are heavily used or frequently duty cycled, you should
check bearings daily using a stethoscope or infrared scanner (or camera, if appropriate).
Check bearing surface temperature with a thermometer, electronic temperature sensing
devices, or stick-on temperature indicating labels. Compare temperature of hot bearings
with the temperatures of normally operating bearings. Check oil rings and watch for
excessive end play.

Rotor/stator inspection. Check air gap between the rotor and stator with feeler gages at least
annually. Measurements should be made at the top, bottom, and on both sides of the stator.
Differences in readings obtained from year to year indicate bearing wear.
Belt inspection. Check belt tension; belts should have about 1 in. of play. Sheaves should be
seated firmly with little or no play. Couplings should be tight, within tolerances, and should
operate without excessive noise. An alignment check should be made on all motor-generator
sets and on motor-load couplings when trouble is suspected.
Brush/commutator inspection. Inspect brushes and commutators of DC motors for
excessive wear. Check brushes for proper type, hardness, conductivity, and fit in brush
holders. Check holder spring pressure with a small scale. In most instances, pressure should
be 2 to 2 1/2 lbs per sq in. of brush cross-sectional area. Call manufacturer or service
company to solve recurring problems of brush chatter, excessive brush wear, and sparking,
streaking, or threading of commutator.
Motor mount inspection. Check mounting bolts, steel base plates for possible warping, and
concrete base for cracking or spalling.
Annually, perform vibration-analysis tests. Excessive vibration may be hard to detect by
hand, but it could be enough to shorten motor life significantly. It can cause bearing failure,
metal fatigue of parts, or failure of windings. The cause of vibration is usually mechanical in
nature, such as excessive belt tension, defective sleeve or ball bearings, misalignment, or
improper balance. The most common cause is the unbalance of a rotating member (the
motor rotor, rotating load, or other drive train component). Simple testing of the motor is
done by uncoupling the load or removing the belts and then running the motor. Electrical
problems also can cause vibration.
Field vibration analysis can be accomplished by using a portable instrument that identifies
vibrations and displays their amplitudes and frequencies.
Motor temperature control. Restricted ventilation will cause a motor to operate at a higher
than desired temperature. Dirt, dust, chemicals, snow, oil, grass, weeds, etc., can clog
ventilation passages of an open-frame motor. Keep motor clean and cool. In poor
environments, blow out dirt with dry compressed air (no more than 50 lbs) as often as
needed.

Open dripproof and totally enclosed motors are protected but must not be installed where
air flow will be restricted or where excessive ambient temperatures might be encountered.
In high-temperature locations, consider the use of energy-efficient motors that operate
cooler than standard motors. Excessive ambient temperatures will shorten motor life.
Pull and disassemble important motors during summer shutdowns for thorough inspection,
testing, cleaning, checking of bearings, couplings or accessories, or complete reconditioning.
Record keeping. Keep accurate records. Perform annual insulation-resistance (IR) and other
appropriate tests. Important motors should also receive a thorough visual inspection, as
well as voltage and current checks. All values should be recorded and compared each year.
The trend of the readings will indicate the condition of the motor and offer a guide to its
reliability.
Basic guidelines to control maintenance
These guidelines will help you maintain motor controls.
Cleanliness. In poor environments, blow out dirt weekly; in normal environments, a
quarterly or semi-annual cleaning should be adequate. Make sure that dust or
contamination is kept off high-voltage equipment. This is important because dust may
contain conducting materials that could form unwanted circuit paths, resulting in current
leakage or possible grounds or short circuits.
Moving parts inspection. Moving parts should operate easily without excessive friction.
Check operation of contactors and relays by hand, feeling for any binding or sticking. Look
for loose pins, bolts, or bearings. If the control is dirty, it should be wiped or blown clean.
Contact inspection. Check contacts for pitting and signs of overheating, such as
discoloration of metal, charred insulation, or odor. Be sure contact pressure is adequate and
the same on all poles; verify with manufacturer's specification. Watch for frayed flexible
leads.
Contact resistance testing. On essential controls, perform contact-resistance tests with a
low-resistance ohmmeter on a regular basis. Proper contact resistance should be about 50
micro-ohms. Record readings for future comparison. This will indicate trends in the
condition of contacts.

Overload relay inspection. Overload relays should receive a thorough inspection and
cleaning. You also should check for proper setting. In general, maintenance requirements
for these relays include checking that the rating or trip setting takes into account ambient
temperature as well as the higher inrush currents of modern, energy-efficient motors. You
also should verify that contacts are clean and free from oxidation and that the relay will
operate dependably when needed. Relays should be tested and calibrated every one to three
years. Special equipment such as an OL relay tester can be used.