How to Troubleshoot 3 Phase AC Motors.

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Three phase induction motors are one of the most popular electric motors commonly
found in processing plants or any manufacturing concern. They are used in situations
where large power is required. The squirrel cage brand is the most popular and they
perform various tasks wherever they are applied.

Because of the critical roles these motors play in any plant, a failure of the motor,
inability to start, noisy operation and sundry other problems need to be remedied as
soon as possible to avoid costly production downtime. The table below gives the
commonly encountered problems in 3 phase squirrel cage induction motors, cause of
problems and what remedy to apply to bring the motor back to production. This
troubleshooting guide can also be applied to other types of three phase induction
motors:

Motor Problem Cause Remedy

Motor fails to start Blown fuses Replace fuse with proper type and rating

Overload Trips Check and reset overload in starter

Improper power supply Check to see that power supplied agrees with
nameplate specifications and load factor

Improper line Check connections with wiring diagram

connections supplied with motor

Open circuit in winding or This is normally indicated by a humming

control switch sound when switch is closed. Check for loose
wiring connections. Confirm that all control
contacts are closing.

Mechanical failure Check to see that motor and drive turns

freely. Check bearings and lubrication

Short circuited stator Indicated by blown fuses. Motor must be

rewound

Poor stator coil Remove end belts. Locate poor connections

connections with test lamp.

Rotor defective Check for broken bars or end rings

Motor may be overloaded Reduce motor load

Motor stalls One phase may be open Check supply lines for open phase

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 Wrong application Change type or size. Consult motor
manufacturer

Overload Reduce load

Low voltage Check that nameplate voltage is maintained.

Check connection.

Open circuit Fuses blown. Check overload relay, stator

and push buttons

Motor runs and then Power failure Check for loose connections to line, to fuses
dies down and to control

Motor does not Motor is applied for the Consult manufacturer for right application of
come up to speed wrong application motor

Voltage too low at motor Use higher voltage on transformer terminals

terminals because of line or reduce load. Check connections. Check
drop conductors for proper size.

Starting load too high Check load motor is supposed to carry at

start.

Broken rotor bars or Look for cracks near the rings. A new rotor
loose rotor may be required as repairs are usually
temporary not permanent

Open primary circuit Locate fault with testing device and repair.

Motor takes too long Excessive load Reduce load

to accelerate and/or
draws high current Low voltage during start Check for high resistance. Adequate wire
(Amps) up size.

Defective squirrel cage Replace with new rotor

rotor

Applied voltage too low Improve voltage at terminals of transformer

by tap changing.

Wrong rotation Wrong sequence of Reverse connections at motor or at

phases switchboard.

Motor overheats Overload Reduce load

while running under
load Frame or bracket vents Open vent holes and check for a continuous
may be clogged with dirt stream of air from the motor.
and prevent proper
ventilation of motor.

Motor may have one Check to make sure that all leads are well
phase open connected.

Grounded coil Locate and repair

Unbalanced terminal Check for faulty leads, connections and

voltage transformers.

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 Motor vibrates Motor misaligned Realign

Weak support Strengthen base

Coupling out of balance Balance coupling

Driven equipment Re-balance driven equipment

unbalanced

Defective bearings Replace bearing

Bearings not in line Line bearings up properly

Balancing weights shifted Re-balance motor

Poly-phase motor Check for open circuit

running single phase

Excessive end play Adjust bearing

Unbalanced line Unequal terminal volts Check leads and connections

current on poly-
phase motors Single phase operation Check for open contacts
during normal
operation Unbalanced voltage Correct unbalanced power supply

Noisy Operation Airgap not uniform Check and correct bracket fits or bearing.

Rotor unbalance Rebalance

Hot bearings Bent or sprung shaft Straighten or replace shaft

general
Excessive belt pull Decrease belt tension

Pulley too far away Move pulley closer to motor bearing

Pulley diameter too small Use larger pulleys

Misalignment Correct by realignment of drive

Hot bearings ball Insufficient grease Maintain proper quantity of grease in bearing

Deterioration of grease or Remove old grease, wash bearings

lubricant contaminated thoroughly in kerosene and replace with new
grease.

Excessive lubricant Reduce quantity of grease, bearing should

not be more than 1/2 filled

Overloaded bearing Check alignment, side and end thrust.

Broken ball or rough Replace bearing, first clean housing

races thoroughly

This troubleshooting guide is by no means exhaustive but can provide guidance for the
resolution of commonly encountered problems as far as poly-phase induction motors
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are concerned.

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