Preventing VFD/AC Drive-Induced

Electrical Damage to AC Motor Bearings

by William Oh, Electro Static Technology

Overview
The use of variable frequency drives (VFDs) to control AC
motors has increased dramatically in recent years. In addition
to their low operating cost and high performance, they save
energy. Today, the challenge facing system designers and
engineers is to minimize damage to AC motors from bearing
current. From its first minute of operation, a VFD induces
destructive voltages that build up on the motor shaft until
they find discharge paths to the frame (ground). In most cases,
the motor bearings present the path of least resistance. Once
voltage is sufficient to overcome the resistance of the oil film
layer in the bearing, shaft voltage discharges, causing electrical
discharge machining (EDM) pits — fusion craters in the race
wall and ball bearings. This phenomenon continues until the
bearings become so severely pitted that fluting, excessive
noise, and failure occur.
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Prevent in g V F D /AC D r i ve - I n d u ce d E l e c tr i c a l D a ma g e to AC M o to r B e a r i n g s

Variable Frequency Drives Due in large part to an increased focus on energy savings, the use of pulse-width-modulated (PWM)
Induce Bearing Currents VFDs to control AC motors has grown dramatically over the last few years. While they offer low operating
costs and high performance, VFDs are not without their problems.
in AC Motors
Shaft voltage induced by VFDs can lead to motor failures. Without some form of mitigation, shaft voltage
discharges by arcing through bearings, a process also known as bearing current. These currents cause
pitting, fusion craters, fluting, excessive bearing noise, eventual bearing failure, and subsequent motor
failure. This is not a small problem. Consider:
• Most motor bearings are designed to last for 100,000 hours, yet motors controlled by VFDs can fail
within one month (720 hours).
• An HVAC system contractor recently reported that, of the 30-60 HP VFD-controlled vane axial fans he
installed in a large building project, two motors failed within six months and 100% of the motors failed
within one year.
• Several large pulp and paper companies surveyed noted that the VFD-controlled AC motors used in
their plants typically fail due to bearing damage within six months.
• The largest motor manufacturer in the United States has cited eliminating drive-related motor failures
as its number one engineering challenge.
• Today, there are dozens of published articles discussing the problems presented by VFD-induced
bearing currents, sharing information and experiences, and suggesting solutions.
• Motor failures caused by VFD-induced bearing currents result in hundreds of thousands of hours of
unplanned downtime, in the United States alone, each year. In addition, these failures decrease ther
performance and mean time between failure of the systems in which they are used.
• With motor price increases, this problem will become even more costly.

Due to the high-speed switching frequencies

Electrical Damage used in PWM inverters, all variable frequency
to Bearings drives induce shaft voltage in AC motors.
During normal operation, the switching
frequencies of the insulated-gate bipolar
Figure 1 transistors (IGBTs) used in these drives
produce voltages on the motor shaft through
Voltage repeatedly builds up on electrostatic induction. These voltages,
the shaft of a VFD-controlled
motor, then discharges through
which can register 70 volts or more (peak-
bearings, damaging them to-peak), are easily measured by touching
and shortening motor life. an oscilloscope probe to the shaft while the
motor it is running (Figure 1).
Bearings are designed to operate with a very thin layer of oil between the rotating ball and the bearing
race. Once these voltages reach a level sufficient to overcome the dielectric properties of the bearing
grease, they discharge through the motor bearing to the motor housing. During virtually every VFD
cycle, induced shaft voltage discharges from the motor shaft to the frame through the bearings, leaving
small fusion craters in the bearing race.
These discharges are so frequent that before long the entire bearing race becomes marked with
countless microscopic pits, which cause bearing frosting. As damage continues, the frosting
increases, eventually leading to noisy bearings and bearing failure. A phenomenon known as fluting
may occur as well, producing washboard-like ridges across the frosted bearing race. Fluting can cause
excessive noise and vibration that, in heating, ventilation, and air-conditioning systems, is magnified
and transmitted by the ducting. Regardless of the type of bearing or race damage that occurs,
the resulting motor failure often costs thousands or even tens of thousands of dollars in downtime
and lost production.
Figure 2 Failure rates vary widely depending on many
factors, but evidence suggests that a
Under an electron significant portion of failures occur only 3 to 12
microscope, a new bearing months after system startup. Because many of
race is smooth, showing today’s AC motors have sealed bearings to
only the typical grooved
track where the bearings keep out dirt and other contaminants,
contact to the wall. electrical damage has become one of the
most common causes of bearing failure in
VFD-driven AC motors.

© 2018 Electro Static Technology 2 Electro Static Technology

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Prevent in g V F D /AC D r i ve -I n d u ce d E l e c tr i c a l D a ma g e to AC M o to r B e a r i n g s

Figure 3 New Bearing Race: Viewed under a scanning

electron microscope, a new bearing race wall is
Pitting occurs after 5400 hours a smooth surface (Figure 2). As the motor runs,
of continuous operation of a a track eventually forms where the bearing ball
VFD-driven motor. Eventually,
the entire bearing race will be contacts the wall. With no electrical discharge
covered with millions of pits, damage, this type of mechanical wear would be
giving the appearance of the only cause of degradation.
a frosted surface. Pitting: Early damage typically takes the form of
pitting (Figure 3). These fusion craters increase
in number and size as each cycle of induced
voltage discharges from the shaft through
the bearings to the frame and ground. Soon
the entire race is covered with millions of pits.
Figure 4 Eventually, as new fusion craters form over old
ones, a “frosted” surface — visible to the naked
VFDs cause concentrated eye — appears.
pitting at regular intervals
along the bearing race wall, Fluting: In a phenomenon known as fluting
forming a “washboard” concentrated pitting occurs at regular intervals
pattern known as fluting. along the bearing race wall, forming a
“washboard” pattern (Figure 4). This pattern
results in vibration and noise. In an HVAC
system, this noise can be transmitted
throughout a facility via air ducts.

Strategies for Mitigating Electrical damage to the bearings of VFD-controlled motors begins at startup and grows
progressively worse. As a result of this damage, the bearings eventually fail. To prevent such damage
Shaft Current Damage in the first place, either the bearings must be shielded or a non-destructive path to ground for the
discharge currents must be created.
Although there are a number of technologies now available to protect AC motor bearings from damage
due to shaft voltage, few meet all the criteria of effectiveness, low cost, and application versatility.
1. Faraday shield: The shield prevents the VFD current from being induced on the shaft by effectively
blocking it with a capacitive barrier between the stator and rotor. However, this solution is extremely
difficult to implement, very expensive, and has been generally abandoned as a practical solution.
2. Insulated bearings: Insulating material, usually a nonconductive resin or ceramic layer, isolates the
bearings and prevents shaft voltage from discharging through them to the frame. This forces current
to seek another path to ground, such as through an attached pump or tachometer or even the load.
Due to the high cost of insulating the bearing journals, this solution is generally limited to larger-sized
motors. Sometimes, high-frequency VFD-induced currents actually pass through the insulating layer
and cause bearing damage anyway. Another drawback is the potential for contaminated insulation,
which can, over time, establish a current path through the bearings.
3. Ceramic bearings: Nonconductive ceramic balls prevent the discharge of shaft voltage through
this type of bearing, forcing the current to seek an alternate path to ground. This technology is very
costly and, in most cases, motors with ceramic bearings must be special ordered and have long lead
times. In addition, because ceramic bearings and steel bearings differ in compressive strength, in many
cases ceramic bearings must be resized to handle mechanical static and dynamic loadings.
4. Conductive grease: In theory, because this grease contains conductive particles, it should provide
a lower-impedance path through the bearing and should bleed off shaft current through the bearing
without damaging discharges. Unfortunately, the conductive particles in these lubricants increase
mechanical wear to the bearing, rendering the lubricants ineffective and often causing premature
failures. This method has been widely abandoned as a viable solution to bearing currents.
5. Grounding brush: A metal brush contacting the motor shaft is a more practical and economical
way to provide a low-impedance path to ground, especially for larger motors. However, these brushes
pose several problems of their own:
a. They are subject to wear because of the mechanical contact with the shaft.
b. They collect contaminants on their metal bristles, which limit their effectiveness.
c. They are subject to oxidation buildup, which further decreases their grounding effectiveness.
d. They require maintenance on a regular basis, which increases their cost.

3 Electro Static Technology

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Prevent in g V F D /AC D r i ve - I n d u ce d E l e c tr i c a l D a ma g e to AC M o to r B e a r i n g s

6. Shaft Grounding Ring: This innovative new approach involves the use of a ring of specially
engineered conductive microfibers to redirect shaft current and provide a reliable, very low impedance
path from shaft to frame, bypassing the motor bearings entirely. The ring’s patented Electron Transport
Technology uses the principles of ionization to boost the electron transfer rate and promote extremely
efficient discharge of the high-frequency shaft voltage induced by VFDs. With hundreds of thousands of
discharge points, the SGR channels shaft current away from AC motor bearings, protecting them from
electrical damage. The AEGIS® SGR is a low-cost solution that can be applied to virtually any size AC
motor in virtually any VFD application.

A More Complete The AEGIS® Ring offers a unique combination of benefits unmatched by other technologies, including:
Solution Scalability: AEGIS® technology is scalable to any size motor regardless of motor frame or shaft size, or
application. Introduced to the market in May 2005, the AEGIS® Shaft Grounding Ring was designed for
motors with shafts from 0.311" to 6.020" including NEMA and IEC frames as well as high-horsepower
AC and DC motors with shaft diameters up to 30". AEGIS® Shaft Grounding Rings have been applied to
power generators, gas turbines, wind turbine generators, AC traction and break motors, cleanrooms and
HVAC systems, and a long list of other industrial and commercial applications.
Installation and maintenance: The AEGIS® Ring is easily installed by sliding the ring over either end
of the motor shaft and locking it in place with simple screw-on mounting brackets or conductive
epoxy. Because no machining is required, the ring can be installed in minutes — even in the field. Once
installed, the AEGIS® Ring requires no maintenance. With no parts to wear out, the AEGIS® Ring lasts
as long as the bearings. A split-ring design allows installation around the shaft without disassembling
attached equipment.
Low cost and high return on investment: One of the key goals in the design of the AEGIS® Ring
was to create true value for the customer. Typically, an AC motor coupled to a VFD costs from $2,400 to
$100,000 or more and may be part of a manufacturing process that generates revenues from $10,000 to
$1,000,000 or more per hour. The cost of installing an AEGIS® Ring in a VFD/AC motor system is very low
when compared to the cost of the overall system, usually less than 1% of the equipment cost.
By preventing electrical damage to bearings, the AEGIS® Ring protects the VFD system from the costly
downtime of unplanned maintenance. In some production applications, even a momentary stoppage
due to motor failure can cost more than $250,000, excluding the cost of repairing the motor.
Motor manufacturers and process engineers in industries where VFDs are used are keenly aware of the
problems and expense caused by electrical damage to bearings. They have expended significant time,
effort, and money to find a solution to this problem. The AEGIS® Conductive Microfiber Shaft Grounding
Ring is the most effective and universally applicable solution to date.

AEGIS® Shaft Grounding Rings outlast and outperform virtually all other shaft grounding technologies.
Their microfiber brushes surround motor shafts with a full 360˚ of conductive microfibers that provide
AEGIS® Rings Outperform millions of contact points for superior grounding protection. Maintenance-free, they last for the full L-10
life of motor bearings, will not clog or jam, and are unaffected by moderate contamination.
Other Shaft Grounding
Technologies
William Oh, the author of this paper and the General Manager of Electro Static Technology, has
extensive design and application experience in both automation and product development, specializing
in passive dissipative technology for mitigating unwanted electrical currents. Mr. Oh is also the inventor
of the Electron Transport Technology on which AEGIS® Shaft Grounding Rings are based.
Electro Static Technology, an Illinois Tool Works company, is a leader in the development and application
of passive ionization technology solutions for industry.

31 Winterbrook Road
Mechanic Falls, ME 04256
(866) 738-1857
[email protected]
www.est-aegis.com

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