Industrial Electrical Shortcomings:
The motor's winding lead wire got damaged:
I received a complaint yesterday evening that one of the motors was not running. The Circuit breaker of that motor was getting trip every now and then. Sometimes, early and sometimes later on. I went there to check it, what was happening over there? When I look at the motor and connected load through it. I saw there was a belt drive system and two out of four belts got damaged. I tried to find the relation in my mind if the belts get damaged, will the motor take load in terms of amperes?
The ethics of troubleshooting is that you try to rectify those shortcomings first what you see through the naked eye. It's my point of view, you guys are allowed to differ it. I called the mechanical team to replace the belts and I kept thinking, was there any link between the belts and the motor's breaker? I could not conclude it. I told the mechanical team to replace all the belts. I would run the motor and check it tomorrow morning because that machine was not in production.
I was trying to find the relation between belts and the motor's amperes. I googled it then I found this line that makes sense but I was not satisfied that belts could play that role.
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Clearly, the torque and power increase in direct proportion to the number of belts. ( Courtesy of Google)
When I got that motor run the next morning. The problem remained the same. Sometimes, the motor started smoothly, and sometimes not but the circuit breaker was getting trip later or sooner. I said to the electrician," Open the motor's junction cover first" I wanted to check it and took readings of the motor winding. Whether we had an issue here or somewhere else. I needed to confirm it. When they uncovered it we found the problem. Have a look at the images what was the problem.
One of the lead wires that was coming through the motor's winding broke. One of the toughest jobs in troubleshooting is to diagnose the exact fault. If you diagnose the fault, It simply means you have done half of your job. Now it will depend on whether you have the same part at the store or you need to do some creative work.
Usually, a lot of distractions come in front of you when you start troubleshooting. Sometimes operators distract you, your colleagues, and the situation around the shortcomings. You have to be firm and focused to troubleshoot the shortcomings. The most important thing is that the machine will let you know whether my issue has been sorted out or not.