(C) 2007, SUCCESS by DESIGN

On the (lo) frequency spectra, the top screen is the RMS current and represents
variations in torque. The regular change, in this case, appears to represent
changes in speed and load, as we will show later.
The middle screen represents the low frequency spectra and, in this case,
represents the modulated current frequencies as they relate to the line frequency
current. In this case, the spectra represents the dB down from the peak current.
The bottom spectra is the demodulated current. The key to the demodulated
current screen is to identify that peaks exist, you cannot do much more than that as
the dB down is in relation to the highest peak on the screen. Instead, you identify
that the peaks exist which should relate to sidebands on the middle modulated
current spectra. Normally, the alert is -75dB and alarm is -65dB or 10dB above the
noise floor.
In this particular case, the large number of sidebands of current around the line
frequency current make it appear as a raised noise floor. The standard report
(automated analysis) will consider this as a rotor bar issue because there is energy
where the ppf would be. In the demodulated current (bottom screen), the raised
floor (very low meaning no misalignment or unbalance) around the rs cursor
(running speed) identifies that the speed was varying.

(C) 2007, SUCCESS by DESIGN

This is also the low frequency screen. However, I have removed the rms current
and demod current and have opened the modulated voltage. As you can see, there
are a large number of peaks around line frequency representing the drive (amplifier)
varying output speed. This is normal when you have varying loads or speeds while
collecting the data with ESA.
If you did suspect rotor bars, the best methods in this instance would be to run the
motor at

(This is not the servo motor classic rotor

fault, ppf sidebands)

(C) 2007, SUCCESS by DESIGN

In this example of a 4160 Volt motor with two broken rotor bars, a common rotor bar
signature is identified as two distinct peaks plus and minus the pole pass frequency
from the supply frequency. Measured in dB, the relative force can be determined,
which provides a method of determining the severity.
One thing has to be considered, when taking readings. As the above machine was
a 4,160 Vac machine, test results were taken from the 0-5 amp current transformers
in the controls. The result is that the peaks will be dampened somewhat.

-dB

Rotor Condition
Assessment

Recommended Action

60

Excellent

None

54 60

Good

None

48 54

Moderate

Trend Condition

42 48

High Resistant
Connection or Cracked
Bars

Increase Test Frequency and Trend

36 42

Broken Rotor Bars Will

Show in Vibration

Confirm with Vibration, Plan Repair / Replace

30 36

Multiple Cracked/Broken
Bars, Poss Slip Ring
Problems

Repair/Replace ASAP

<30

Severe Rotor Faults

Repair/Replace Immediately

(C) 2007, SUCCESS by DESIGN

These are the dB down values of ppf and the expected issues if there were two specific ppf peaks.

(C) 2007, SUCCESS by DESIGN

In the calculations screens of the software, in addition to the results, you can show
the base power information, the identified line frequency, speed, pole pass
frequency and the voltage and current total harmonic distortion. The left screen
also identifies the calculated motor load, efficiency, output power and torque. In
your much smaller servo motors, this information will not be accurate and the motor
output information will not show if you take just one phase or current only. Knowing
the motor speed (and confirming it on the low frequency spectra) and if you are able
to obtain the number of rotor bars and stator slots you can identify most rotor and
stator faults.

Motor Faults
Type of Fault

Pattern (CF)

Stator Mechanical

CF = RS x Stator Slots
LF Sidebands

Rotor Indicator

CF = RS x Rotor Bars
LF Sidebands

Static Eccentricity

CF = RS x Rotor Bars
LF and 2LF Sidebands

Mechanical Unbalance
Dynamic Eccentricity

Stator Electrical (Shorts)

CF = RS x Rotor Bars
LF Sidebands and 2LF Signals
CF = RS x Rotor Bars
LF and 2LF Sidebands with Running Speed
Sidebands
CF = RS x Stator Slots
LF Sidebands with Running Speed Sidebands
(C) 2007, SUCCESS by DESIGN

These are the standard motor faults which will be found in the high frequency
spectra (which we will visit next).

(C) 2007, SUCCESS by DESIGN

When you open the high frequency spectra, the two left screens will be the voltage
and current waveforms across the first 0.05 seconds. The top screen represents
what the current waveform will look like (roughly) and the bottom screen represents
what the voltage looks like. As this is a VFD/amplifier, the voltage will show a rough
approximation of the output pulses from the drive. Both of these waveforms appear
normal for a PWM output.

(C) 2007, SUCCESS by DESIGN

These screens are the one second representations of the previous data. As you
can see, the current is remaining roughly steady while the voltage appears to be
changing frequency.
What the load is demanding will determine if this is normal or not.

(C) 2007, SUCCESS by DESIGN

To the right of the voltage and current waveforms will be the high frequency voltage
and current spectra. In the case of ffts from VFD/amplifier outputs, the above
spectra is almost normal. The raised noise floor across the entire spectra of voltage
normally indicates that the ground reference for the motor and drive are different, or
that there is noise on either the motor or drive grounds (or both). This should be
corrected as a drive or amplifier requires a good ground reference, in relation to the
motor, for proper operation.
As far as the analysis goes, if current peaks are higher than voltage peaks, they
would represent issues downstream from the point of test towards the motor/servo.
If the voltage peaks are higher than current, they represent the incoming power
frequencies, similar peaks in current are sympathetic.

(C) 2007, SUCCESS by DESIGN

By overlaying the voltage and current spectra, you would look for any current peaks
(blue, in this case) above voltage peaks (black, in this case). As there are few, if
any, blue peaks above black, then we can assume that the motor being tested, and
the associated load, are in fairly good shape and that the peaks (which are above
the small red and green tags at the bottom) are harmonics of voltage and current
line frequency.

10

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Ph: 800 392-9025 or 860 575-3087

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http://www.motordoc.net
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