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Typical Causes of Winding Failures

Unfavorable operating conditions can dramatically shorten the life of a three-phase stator winding. Common causes of winding failures include single-phased failures from power supply issues, short circuits from contaminants or vibration between turns or coils, ground faults from contaminants or abrasion, unbalanced voltages from unequal loads or connections, overloads exceeding motor ratings, locked rotors producing high currents, and voltage surges from switching or lightning. Identifying failure causes can help take preventive measures to avoid future issues.

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Mark Nelson
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546 views4 pages

Typical Causes of Winding Failures

Unfavorable operating conditions can dramatically shorten the life of a three-phase stator winding. Common causes of winding failures include single-phased failures from power supply issues, short circuits from contaminants or vibration between turns or coils, ground faults from contaminants or abrasion, unbalanced voltages from unequal loads or connections, overloads exceeding motor ratings, locked rotors producing high currents, and voltage surges from switching or lightning. Identifying failure causes can help take preventive measures to avoid future issues.

Uploaded by

Mark Nelson
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Typical Causes of Winding Failures

in Three-Phase Stator Windings

Good Stator Winding

Unfavorable operating conditions–


electrical, mechanical or environmental–
can dramatically shorten the life of a three-
phase stator winding. The winding failures
illustrated below typify what can happen in
such circumstances. They are shown here
to help you identify the causes of failure, so
that, where possible, you may take
preventive measures.

Compare the new stator winding (right) with


the failed windings pictured below.

1 Winding Single-Phased
(Wye-Connected)

A single-phased winding failure is the


result of an open in one phase of the
power supply to the motor. The open
is usually caused by a blown fuse, an
open contactor, a broken power line or
bad connections.

2 Winding Single-Phased
(Delta-Connected)

A single-phased winding failure is the


result of an open in one phase of the
power supply to the motor. The open
is usually caused by a blown fuse, an
open contactor, a broken power line or
bad connections.

3 Winding Shorted Phase-to-


Phase

This type of insulation failure is


typically caused by contaminants,
abrasion, vibration or voltage surge.
4 Winding Shorted Turn-to-
Turn

This type of insulation failure is


typically caused by contaminants,
abrasion, vibration or voltage surge.

5 Winding With Shorted Coil

This type of insulation failure is


typically caused by contaminants,
abrasion, vibration or voltage surge.

6 Winding Grounded at Edge of


Slot

This type of insulation failure is


typically caused by contaminants,
abrasion, vibration or voltage surge.

6A Winding Grounded at Edge of


Slot

This type of insulation failure is


typically caused by contaminants,
abrasion, vibration or voltage surge.

7 Winding Grounded in the Slot

This type of insulation failure is


typically caused by contaminants,
abrasion, vibration or voltage surge.
8 Shorted Connection

This type of insulation failure is


typically caused by contaminants,
abrasion, vibration or voltage surge.

9 Phase Damage Due to


Unbalanced Voltage

Thermal deterioration of insulation in


one phase of the stator winding can
result from unequal voltage between
phases. Unequal voltages usually are
caused by unbalanced loads on the
power source, a poor connection at
the motor terminal, or a high
resistance contact (weak spring).

Note: A one-percent voltage


unbalance may result in a six- to ten-
percent current unbalance.
10 Winding Damaged Due to
Overload

Thermal deterioration of the insulation


in all phases of the stator winding
typically is caused by load demands
exceeding the rating of the motor.

Note: Under-voltage and over-voltage


(exceeding NEMA standards) will
result in the same type of insulation
deterioration.
11 Damage Caused by Locked
Rotor

Severe thermal deterioration of the


insulation in all phases of the motor
normally is caused by very high
currents in the stator winding due to a
locked rotor condition. It may also
occur as a result of excessive starts or
reversals.

12 Winding Damaged by Voltage


Surge

Insulation failures like this usually are


caused by voltage surges. Voltage
surges are often the result of
switching power circuits, lightning
strikes, capacitor discharges and
solid-state power devices.

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