With 217 exhibitors, almost 400 booths, and 36 first-time exhibitors, the 2017 EASA Convention was a success by any measure.

The AEGIS® sales team was busy at our booth demonstrating the AEGIS® Shaft Voltage Tester™ Digital Oscilloscope, and encouraging visitors to try the scope for themselves.  Elsewhere in the booth,  we discussed the effectiveness of AEGIS® SGR Rings for low-voltage motors and AEGIS® PRO Series Rings for high power AC or DC motors and medium-voltage motors and generators in channeling harmful shaft voltages away from bearings and safely to ground.

With 6 rows of conductive microfiber brushes and millions of shaft contact points, AEGIS® PRO Series Rings have greater current-carrying capacity than smaller AEGIS® SGRs.  They are available in solid- and split-ring versions with optional universal mounting brackets.  The PROSLR specially designed for severe environments, with dual O-ring dust/debris barriers that prevent dirt, liquids, and other contaminants from interfering with contact of the ring’s brushes with the motor shaft.

Brad Chrudimsky, Marketing Communications Specialist-Electrical at Baldor

Also on display was the AEGIS® PROMR ring, comprising an AEGIS® PROSL Ring and an AEGIS® SGR monitoring ring separated by a non-conductive phenolic plate.  The AEGIS® PROMR provides bearing protection for large motors combined with remote monitoring capabilities.  It is ideal for monitoring remotely located or hard-to-access motors.

This year, we had help at our booth from XView Asia Industrial, our distributor for China and the Far East.  We were joined by William Wu, Sales Manager, and Desmond Lau, Sales Engineer.

As if the show wasn’t busy enough, our Sales Manager Adam Willwerth made time to star in a video about the benefits, selection, and installation of AEGIS® Rings.  To view it, click here.

But promotion of AEGIS® Rings — and the bearing protection they provide — extended well beyond the AEGIS® booth.  In

Chris Voll, Distribution Product Manager – Marathon & Century Motors/Commercial & Industrial Motors

fact, AEGIS® Rings and motors with rings factory installed could be seen in the booths of major motor manufacturers throughout the show.  In response to the heightened awareness of VFD-induced bearing damage, a growing number of motor manufacturers now offer AEGIS® Bearing Protection as standard or as mod shop options on their motors.

 

Baldor offered its catalog line of NEMA Premium Super E motors with AEGIS® Rings factory-installed.

Regal Beloit also promoted its motors with AEGIS® Rings factory-installed.  These include Marathon BCP Motors and award-winning Marathon Cooling Tower Motors, Leeson’s Extreme Duck Washdown Motors, and Century Motors’ option program through which it will factory install AEGIS® Rings on a wide range of motors.

Nestor Blanquer Vazquez, Export Sales; and Toby Johnston, both of WEG Electric, exhibited WEG’s line of AC Square Motors with AEGIS® Rings available as an option.

 

WEG Electric exhibited several of its motors with AEGIS® installed.  WEG offers AEGIS® in ODP and TEFC motors in cast iron or rolled steel, for general-purpose and close-coupled pump applications.

 

Several AEGIS® distributors also exhibited at the show including Bartlett Bearing, EIS, and Midpoint Bearing.

Finally, two manufacturers whose bearing isolators incorporate AEGIS® Rings — Garlock and Flowserve — completed the list of companies offering and promoting AEGIS® technology.

There are a number of factors to consider when deciding whether to repair or replace a damaged motor.  These include (but are not limited to) the age and general condition of the motor, the availability of a suitable replacement (including the size and horsepower), and the energy efficiency of the motor versus a newer motor.

But if you decide that a motor is worth repairing, protecting it from electrical bearing damage makes good sense from both an operational and a financial standpoint.  And installing an AEGIS® Bearing Protection Ring — or having your motor repair shop install one — is one of the least expensive “insurance policies” you can buy…especially if the motor is controlled by a variable frequency drive (VFD).

By controlling the speed of motors, VFDs can improve process control and reduce energy usage/costs by 30% or more. But VFDs induce voltages on the Pitting, frosting, & fluting bearing damage from shaft voltage dischargeshafts of the motors they control — voltages that can damage bearings. And even motors not controlled by VFDs can sustain bearing damage due to stray currents.

Without bearing protection, shaft voltages can discharge through bearings, causing pitting (tiny fusion craters in metal bearing surfaces), frosting (widespread pitting), or fluting (washboard like ridges in the bearing race due to the operational frequency of the drive) and complete bearing failure — sometimes in as little as 3 months!

To protect VFD-driven motors from electrical bearing damage, long-term bearing protection is needed.  As proven in millions of installations worldwide, AEGIS® Shaft Grounding Rings channel harmful voltage discharges away from bearings and safely to ground, protecting motor bearings for their full L10 life.

AEGIS® SGR Rings are available for low-voltage, low power motors, while AEGIS® PRO Series Rings are designed for medium-voltage motors, generators, and turbines, as well as large low-voltage AC motors (500 HP or greater) and DC motors (300 HP or greater).

AEGIS® Rings are available in solid rings (for installation before motors are put into service) and split rings (for fast, easy installation on coupled or in-service motors).  AEGIS® uKITs include an AEGIS® Ring (solid or split) and a set of mounting brackets that speed and simplify installation on motors with shaft shoulders, slingers, or other end bell protrusions.

Most motor repair shops can install AEGIS® Rings in-house or in the field, using best practices to protect new, in-service, or refurbished motors.

For motors up to 100 HP, an AEGIS® Ring is typically all you need to protect motor bearings and coupled equipment from electrical bearing damage.

Motors greater than 100 HP and medium-voltage motors, however, are subject to high-frequency circulating currents as well as capacitive shaft voltage dischargeAEGIS PRO Ring installed with brackets on a large motor bearing current.  So to adequately protect these motors, install an AEGIS® Ring on the drive end of the motor and an insulated bearing on the non-drive end.  For low-voltage motors less than 500 HP, use an AEGIS® SGR.  For low-voltage motors greater than 500 HP or medium-voltage motors, use an AEGIS® PRO Series Ring.

Regardless of the type of AEGIS® Ring you install, be sure to thoroughly clean the motor shaft and apply AEGIS® Colloidal Silver to the shaft in the area where the ring’s microfiber brushes will contact it.  Or ask your local motor shop to install AEGIS® Rings on any motors they repair for you!

To download an AEGIS® Bearing Protection Handbook which details best practices for diagnosing failed motors, testing in-service motors for damaging shaft currents, and protecting at-risk motors from electrical bearing damage, click here.

And if you decide that a motor is not worth fixing, choose a new replacement motor with an AEGIS® Ring factory-installed either internally or externally.  For a list of manufacturers that offer motors with AEGIS® Bearing Protection Rings factory-installed, click here.

AEGIS Rings have worked for years to improve reliability and sustainable operatuion of HVAC and Pump motors.   Case in point: Harvard University’s Campus services Facility Maintenance Operations (FMO) “offers Motor Shaft Grounding, a maintenance program that prevents bearing failure and significantly extends motor life.”

https://www.campusservices.harvard.edu/system/files/documents/950/Motor%20Shaft%20Grounding.pdf

Variable frequency drives (VFDs) present a compelling option for energy savings in sustainable building projects. Power usage in continuously running centrifugal pumps and fans decreases notably with input modulation by a VFD. For example, a 20% reduction in fan speed can reduce energy consumption by nearly 50%. VFDs also introduce their own sustainability problems, however. VFD-induced shaft currents can damage bearings, leading to shorter motor life and costly repairs. Shaft grounding technology such as the AEGIS Shaft Grounding Ring offers a sustainable solution to this problem. Unfortunately, most new construction projects including VFD-driven motors do not utilize this effective option.

The university maintenance department has spearheaded a campus-wide sustainability drive starting with their own Platinum LEED certified headquarters. A major component of this has been a testing program for VFD-driven HVAC motors. Maintenance technicians employ oscilloscopes and voltage measuring probes to ascertain the presence of shaft voltage. When harmful voltage levels are detected, the maintenance department may recommend the installation of an AEGIS ring. Already successfully employed in multiple new buildings on campus, expanding the AEGIS ring to existing motor setups that require bearing protection continues to increase campus-wide sustainability.

The University Test Case

In December 2009, the ring’s manufacturers installed their product on two VFD-controlled HVAC motors in the maintenance headquarters building as a demonstration of the new program. The identical three year old Baldor 7.5HP motors respectively powered a chilled water pump and an air supply fan. With the VFD set at 60HZ, the first motor was running at 1,776rpm. The oscilloscope measured peak-to-peak discharges of 61 volts. Results showed rapid voltage collapses at the trailing edge of the waveform, typical of the electrical discharges that damage bearings. After the reading, technicians cleaned the shaft and installed a split AEGIS ring. Follow-up test results displayed the discharge plot as a straight line, indicating that the AEGIS ring diverted shaft voltage discharges.

Pump Motor with AEGIS Ring installed with EP2400 Conductive Epoxy

The second motor was tested under identical conditions and measured 50.8 volts peak-to-peak shaft discharge. Due to the limited accessibility of this motor, application of a hand-held heater sped epoxy curing in the AEGIS ring installation. After the complete installation, a new test read only 380 millivolts peak-to-peak, again indicating the AEGIS ring successfully diverted shaft voltage discharges to ground.

Conclusion

VFDs provide a compelling option for energy savings in sustainability-minded design. However, unless a product such as the AEGIS Shaft Grounding Ring mitigates the risk of bearing damage, repair costs could outweigh any savings. While this problem remains best addressed in the design stage of the system, the university case study effectively demonstrates the potential to retrofit previously installed motors with shaft grounding technology. Once installed, an AEGIS ring requires no maintenance and lasts for the life of the motor, providing effective protection against shaft voltage.

An array of motors with AEGIS factory-installed http://www.est-aegis.com/oems.php

Most motor manufacturers have product lines with AEGIS Rings factory installed.

More information about the university case study can be found here.

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