One Hour of work!!!!!
This Fan Motor drawing between 82 – 88 Amps was measured with the ALL TESTPro MotorGenie with a 26% resistive imbalance in the Isolator.
On Removal of the Insulation Tape the Crimp Quality was found to be Poor.
The As Found resistances for the Circuit
T1-T2 0.08 Ohms
T1-T3 0.05 Ohms
T2-T3 0.06 Ohms
As Left Resistances across all three phases were 0.00 Ohms, less than 10 milliOhms.
A Hydraulic Crimp tool was used with a correctly selected wide crimp die, with the cable size, Lug Size Matching.
Note: The hydraulic Crimper provides a crisp Hexagon termination that fuses the Copper Cable & Lug in what is called COLD FLOW.
The resultant Termination has very low resistance.
The Original Crimp terminations have utilized a rotational die crimper which has a smaller die width and has resulted in a high resistance termination on all six terminations.
3Phi Reliability recommend the use of Hydraulic Crimp Tools as the Quality is more consistent.
The As Left Test shows the resistances less than 10 milli Ohm on all six terminations.
As Found compared to As Left Vibration Analysis shows a significant difference in twice line Frequency Vibration of the Motor.
Energy Savings from the Terminations
T1-T2 I^2R loss 578 Watts
T1-T3 I^2R loss 361 Watts
T2-T3 I^2R loss 433 Watts
9620 kWhr Saved per Annum at 80% duty
1924 GBP Energy Savings just the Termination Losses
Note: These Energy Savings only account for the Isolator Resistance Change.
A motor that is supplied with an unbalance Voltage as in this case will run with a higher loss and this energy loss is likely to be far greater than the 1924 GBP per Annum.
IT IS OUR ENERGY