A Guide To AC Motor Repair and Replacement

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A Guide To
AC Motor
Repair And
Replacement
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Reliable
Solutions
Today
A Guide To AC Motor Repair And Replacement
Table Of Contents
Introduction ............................................................................................................................ 1
Plan Ahead ............................................................................................................................. 2
Why Motors Fail ..................................................................................................................... 2
Making The Decision To Repair Or Replace .............................................................................. 3
Obtaining Quality Motor Repairs .............................................................................................. 8
Specifying A Motor Rewind...................................................................................................... 11
Evaluating And Selecting A Motor Service Center ..................................................................... 13
Obtaining Motor Repairs Of The Highest Quality...................................................................... 15
EASAs Quality Initiatives ........................................................................................................ 16
About EASA .......................................................................................................................... 17
Appendix: Motor Repair Procedures ........................................................................................ 18
References............................................................................................................................. 21
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Prepared by Electrical Apparatus Service Association, Inc. in cooperation

with the U.S. Department of Energys Motor Challenge Program.
Copyright1999 Electrical Apparatus Service Association, Inc.
1331 Baur Blvd., St. Louis, MO 63132, 314-993-2220.
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Reliable Solutions Today!
Introduction
Motors never fail at a good time. Production stops; workers stand idle; deliveries are missed. The
pressure to get back in operation quickly often leads to snap decisions to repair or replace the failed
motor. But the best time to make such decisions is before a breakdown occursnot during a crisis.
Thats why its so important to plan ahead and take a proactive approach to motor system
management.
A good first step is to make a list of all the motors at your facility. This should include the type, size
and application of each motor, as well as its age, maintenance and repair history, operating conditions and environment, and annual energy cost (or hours of operation). By examining this
information, its often possible to determine ahead of time which motors to repair or replace when a
failure occurs. It can even help in spotting application problems that may be contributing to or
causing failures.
Taking a proactive approach to motor system management can also suggest opportunities for improving performance or reducing energy costs, whether by redesigning a motor to better suit its
application or replacing it with a more energy efficient model. Its also beneficial for identifying
critical applications for which it makes sense to replace a failed motor but then have it repaired for
use as a spare.
The purpose of this booklet is to encourage end users to take a more proactive approach to motor
system management. It provides helpful information for making informed repair or replace decisionsbefore the next motor fails. Included, too, are guidelines for selecting a qualified vendor to
repair or replace failed equipment, tips on how to specify repairs, and explanations of typical repair
procedures.
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The booklet focuses on the workhorses of industry1 to

200 horsepower, three-phase, squirrel-cage induction
motors, rated at 600 volts or less. Although many of
the principles also pertain to larger motors, the
rebuilding procedures described may not apply
for machines used in hazardous locations.
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Plan Ahead
Proactive motor system management is the key to making a cost-effective decision when a motor
fails. Start by making a complete list of the motors at your facilitye.g., types, sizes, applications,
operating conditions, and so forth. Helpful software called MotorMaster is available for this purpose
from the U.S. Department of Energy (DOE) and Allied Partners in its Motor Challenge Program.1
EASA service centers and other qualified vendors also may be able to assist in this area of motor
management.
Next, based on this information, develop and implement a motor repair/replacement policy. This
will ensure that everyone who makes repair/replace decisions will know what to do in almost every
situation.
A good motor repair/replacement policy should factor in motor type and size, age, repair history,
any special mechanical and electrical features, the application, and the operating conditions and
environment. It also should consider energy costs, the cost of downtime, and the cost and availability of repairs and replacements.
Once a motor repair/replacement policy has been established, it frequently is possible to take the
next step toward more effective motor management. Analysis of the motor inventory data, for example, may indicate that spares should be on hand for certain key motors. Performance trending
and close monitoring of maintenance functions also may help minimize costly, unexpected downtime by targeting motors for repair or replacement before they fail. In other words, taking a
proactive approach to motor management can lead to fewer crises, better decisions, and reduced
costs.
Why Motors Fail

Most motor failures are due to mechanical causes, the largest percentage of which are associated
with bearing failures. The easiest way to prevent premature failures and maximize motor life is to
perform simple maintenance procedures and inspections regularly.
Recommended Maintenance Procedures [2]

Follow the manufacturers recommended lubricant and lubrication
requirements.
Identify and correct excessive vibration.
Clean accumulated dust and dirt from

the motor and ventilation passages.
Detect and dry moisture in the

windings.
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Install properly sized overload

protection.
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Even with regular maintenance, motors eventually

Distribution Of Failures On
will fail. When this occurs,
Failed Components [3]
an EASA service center or
Shaft or
other qualified vendor can
Rotor Bars/
Coupling
External Device
End Rings
provide quality service and
2.44%
15.58%
4.70%
repairs or replacement moStator Winding
Not Specific
15.76%
tors. EASA service centers
15 - 20%
also can diagnose the cause
of the failure to help
prevent a recurrence and
advise whether its best to
repair/rewind the motor or
replace it with a more effiBearings
cient model that is also
51.07%
better suited to the operating conditions and
environment of the application. Many also offer ongoing motor system management and maintenance programs to ensure long, efficient operation and to minimize unexpected shutdowns.
Making The Decision To

Repair Or Replace
As mentioned earlier, the best way to avoid making hurried decisions when a motor fails is to plan
ahead. Analyze the economics of repair and replacement for the motors in your facility and develop
a comprehensive motor repair/replacement policy. Again, MotorMaster software thats available from
the U.S. Department of Energy (DOE) and Allied Partners in its Motor Challenge Program can be
helpful here.
Whether you are developing a repair/replace policy or deciding whether to repair or replace a failed
motor, the most important factor usually is downtime. But other variables are notable, too, including the type, size, age and maintenance history of the motor, special electrical or mechanical
features, the cost to repair or replace the motor, and operating costs.
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Sometimes the best decision is fairly obvious, based on the cost of a new motor versus that of repair. At other times, it makes sense to perform a simple payback analysis, factoring in all the costs,
variables, and other considerations discussed below. The important thing to remember is that an
investment in repair or replacement is not just a one-time cost. Other expenses should also be considered, including installation, maintenance, and energy costs for the life of the motor.
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Downtime. Production downtime generally is THE key factor considered when a motor system
breaks down. Lost production means idle workers, missed deadlines, and disappointed customers.
The only way to deal with the reality of motor failure effectively is to plan ahead. Develop information on the types and sizes of motors that operate your most crucial applications. If possible, build
an inventory of spare motors that can serve as replacements for these critical production
applications.
Many companies cannot afford to keep an inventory of spare
motors. Even so, it is important to maintain detailed information about all the motors in the facility. Such
information is useful when contacting service centers and
other motor vendors about repair services or to determine if they commonly stock particular models.
Whether repair or replacement will be faster will depend
upon the size and type of motor, stock availability, and
the service centers production schedule. It usually takes
three to five work days to repair a motor in the 1 to 200 hp
range, but on fast turnaround jobs the time often can be
shortened.
Replacements for most general-purpose open dripproof (ODP) and totally enclosed fan-cooled
(TEFC) motors under 100 hp are stock items at many EASA service centers and other vendors. Rush
orders for general-purpose motors in larger sizes (100 to 500 hp) can often be delivered within two
to four days, whereas special motors and motors over 500 hp could take several weeks to obtain.
When time is criticalas it almost always ischeck with the service center to determine a realistic
delivery schedule for repair and replacement. Keep in mind that work loads at service centers may vary
with the season and other business factors. Above all, let the service center know when fast turnaround
is essential. Most are sensitive to customer needs and will work hard to get the repair completed as
quickly as possible. Most also pride themselves on doing the job right the first time, so avoid asking
them to cut corners to get the motor running sooner. Remember, any compromises made in the quality of the repair could lead to higher operating costs or even premature failure.
Reliability Of Repaired/Rewound Motors. Before deciding to have a motor repaired
or rewound, its reasonable to ask if the repaired motor will be as reliable as a new one. While no
studies to date directly address this issue, the quality of the materials and workmanship that go into
properly repaired/rewound motors often surpass manufacturers design specifications.
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As an example, to improve reliability of rewound motors many service centers routinely upgrade insulation system components to a higher temperature class than that used by the original manufacturer
(e.g., from Class B to Class F or H). This significantly improves the motors ability to withstand higher
temperatures, thereby reducing the possibility of premature failure. Insulation upgrades of this kind
often equal or exceed the temperature class of even todays highly reliable energy efficient motors.
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Many service centers also offer a range of other repair options aimed at improving reliability, including use of premium grades of magnet wire, improved methods of applying insulating varnish, epoxy
treatments, precision balancing of rotating elements, proper bearings, and higher temperature lubricant. Of course, well documented quality assurance systems, repair practices designed to maintain
motor efficiency, and extensive testing protocols are among the other ways that many service centers
ensure that the repaired motor will operate as efficiently and at least as reliably as it did before it
failed. EASA service centers also repair motors according to EASAs Recommended Practice [4]
and, at a minimum, back their work with EASAs Limited Warranties [5].
Efficiency Of Repaired/Rewound Motors. Does repairing or rewinding affect motor
efficiency? Studies show that motors that are rewound or repaired using industry best practices
maintain their original operating efficiencies [6].
To assure that the repaired motor will retain its original efficiency, use a service center that adheres
to EASAs Recommended Practice (or equivalent repair specifications) and follows the repair procedures from EASA Tech Notes 16 & 17 that are summarized on Page 11 [7].
Application Considerations. To assure proper performance, analyze the speed/torque
requirements of the application before replacing a motor. Generally speaking, the replacement
should have torque equivalent to that of the old motor. For centrifugal applications, the replacement
should also have a full-load speed equal to or less than that of the original motor. Finally, be sure to
consider whether any special couplings, mounts or adaptors will be needed for a new replacement
motor or a spare from inventory. Application issues can be complex, and EASA sales and service
centers usually can help.
Repair And Replacement Costs. Motor failures often result in seized bearings, burned
out windings, or both. EASA and other qualified service centers routinely repair such damage, so
repair estimates are relatively straightforward. For more complex repairs (e.g., a bent or broken
shaft or a cracked frame), get a repair quote before going furtherespecially if the economics of
the repair/replace decision are in doubt.
This is also the time to check on the cost and availability of a replacement and to reevaluate the
application and operating conditions. In some cases, there may be opportunities to improve performance or reduce operating costs.
Of course, if the failed motor has special electrical or mechanical features, repair frequently is the
best option. Such motors normally are well suited for their applications and will continue to give
good service after repair or rewinding.
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Operating Costs And Motor Efficiency. When making a repair/replace decision, consider the energy efficiency of the present and replacement models, the utility rates and the hours of
operation. Where utility rates and usage are low, the payback may be longer. Be sure to calculate
payback based on the difference between repair and replacement costs, taking into account any
modification costs associated with the new motor.
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Be Proactive. As mentioned throughout this booklet, it makes sense to know as much as

possible about your motor system application requirements and operating environments. Communicate this information when shopping for a service center or other motor supplier. Learn as much as
possible about the services and products offered by prospective vendors. Develop a motor repair/
replacement policy. By planning ahead, you will be assured of making the right repair/replacement
decision each time.
Calculating Energy Cost Savings

To determine the payback for buying an energy-efficient replacement instead of repairing a failed
motor, first calculate the energy cost savings and the demand cost savings for the two motors [8].
Energy Cost Saving*
Demand Cost Saving
100 100
S = 0.746 x Hp x C x N
Eb Ea
100 100
x MDC x NM
S = 0.746 x Hp
Eb Ea
Where:
S
Savings in dollars per year
Hp
Horsepower rating of the specified load

(hard to measure in the field; .75 load is a
reasonable substitute)
Energy costs in dollars per kilowatt hour
Running time in hours per year (how long

the motor runs, not process time)
Ea
Efficiency (%) of Motor A (new replacement) at the specified load (or from motor
nameplate, DOEs MotorMaster software, or
average motor efficiency from 1994i.e.,

not meeting NEMA Standard 12-10.)
Eb
Efficiency (%) of Motor B (repaired motor) at the specified load (or from NEMA
MG 1, Table 12-10, on Page 7, or DOEs
MotorMaster software)
MDC
Monthly demand charge
NM
Number of months per year demand charge

applied
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* Applies to motors operating at specified constant load. For varying loads, apply to each portion of the cycle where load
is relatively constant for an appreciable period of time. Total savings is the sum of the savings for each load period.
(The equations do not apply to motors on pulsating loads or on loads that cycle at rapidly repeating intervals.)
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Calculating Simple Payback

Calculate the simple payback for an energy-efficient replacement over repairing the failed motor as follows [9].
SPB =
NC + IC - RWC - UR
ECS + DCS
Efficiency Ratings
Nominal Full-Load Efficiencies
Energy Efficient 1800 Rpm Motors
Where:
HP
SPB
Simple paybacki.e., number of years required to

pay back the difference in cost
NC
New motor cost
IC
Incremental installation costs, if any (motor of different hp, speed, or frame size may require new wiring,
mounts, sheaves, pulleys, belts, modifications, etc.)
RWC
Rewind/repair cost (from quote or Vaughens Price

Guide)
UR
Utility rebate (if available)
ECS
Energy charge reduction (from Energy Cost Saving

equation).
DCS
Demand charge savings (from Demand Cost Saving

equation)
The higher the SPB, the longer the payback of replacing the motor.
1 hp
1.5-2 hp
3 hp
5 hp
7.5 hp
10 hp
15-20 hp
25 hp
30 hp
40-50 hp
60 hp
75 hp
100 hp
125 hp
150-200 hp
TEFC
82.5%
84.0%
87.5%
87.5%
89.5%
89.5%
91.0%
92.4%
92.4%
93.0%
93.6%
94.1%
94.5%
94.5%
95.0%
ODP
82.5%
84.0%
86.5%
87.5%
88.5%
89.5%
91.0%
91.7%
92.4%
93.0%
93.6%
94.1%
94.1%
94.5%
95.0%
Reference: NEMA MG 1, Table 12-10.

An EASA service center or qualified motor
supplier can assist in determining efficiency
values for speeds other than 1800 rpm.
Summary
The best repair/replace decisions are made beforehand, not during a crisis. Be proactive. Learn as
much as possible about your motor system application requirements.
Reevaluate each motor and application

to identify opportunities for improving
performance and reducing operating
costs.
Identify critical applications and, if possible, inventory spare motors for them.
Develop and implement a motor repair/
replacement policy.
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Then:
Compile complete information about all
the motors at your facilitye.g., types,
sizes, maintenance and repair histories,
ages, applications, operating conditions, special electrical and mechanical
features, and annual energy costs.
Communicate this information when
shopping for a service center or other
motor supplier.
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Some factors that may inform the decision to repair or replace include:
Importance of having the motor back in

service immediately.
Simple payback analysis.
Cost and availability of repair service as

compared with those of a new motor.
Type and size of motor (e.g., hp, efficiency

rating)
Age and repair history of the motor.
Application (speed/torque requirements).
Maintenance and capital budgets.
Special features (electrical and mechanical).
Electrical operating costs and hours operated annually.
Obtaining Quality Motor Repairs

When repair is the best option, quality
is important. Select a service center that
adheres to EASAs Recommended
Practice (or comparable repair standards) and uses industry best practices
to maintain motor efficiency and reliability (see Page 11).
Motor Loss Distribution

(100% Full Load) [10]
Stray Load
Losses
10 - 15%
Friction &
Windage Losses
5 - 10%
Stator Winding
Losses
35 - 40%
Motor Losses and

Efficiency
To understand how repair procedures
(good and bad) affect motor efficiency,
it helps to know something about
motor losses.
Stator Core
Losses
15 - 20%
Rotor Losses
15 - 20%
Whether new or rewound, all motors give off (or lose) a portion of the input electrical power as
heatcalled motor losses. If the losses increase, the motor will run hotter and therefore less efficiently, using more energy to do the same work as before. The added heat due to increased losses
also will speed the rate at which the insulation system will deteriorate, thereby shortening the life of
the motor. In fact, every increase of 10 C in the temperature of the winding can reduce thermal insulation life by half.
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Motor losses are either fixed or variable, both of which can be affected by poor repair practices.
Fixed or no-load losses remain constant over the full operating range of the machine. They include
stator core losses as well as friction and windage losses.
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Motor Losses
Type Of Loss
Cause
Can Be Increased By
Stator Core Losses
Energy used to magnetize core

material (hysteresis)
Overheating the stator core during

winding removal
Losses due to magnetically induced

circulating currents in the stator core
(eddy currents)
Grinding or filing the stator slots
Energy used to overcome

bearing friction
Installing bearings of incorrect

type or size
Energy used to overcome air movement from the rotor and cooling fan
Damaging or improperly
installing the bearings
Friction And
Windage Losses
Sandblasting the core
Using the wrong size or type of fan

Stator Winding Losses
(Variable I2R Losses)
Heating that occurs as current

flows through the resistance of
the stator winding
Installing the wrong type of seals
Rotor Losses
Heating that occurs as current flows

through the resistance of the rotor
bars and end rings
Machining the stator or rotor
Changing the design of the winding
Damaged rotor cage

Poor connections between bars
and end rings
Wrong or improperly installed bars
Stray Load Losses
All residual losses not fully accounted

for by other types of variable losses
(Not applicable)
Variable losses change with the load. They occur because the flow of current must overcome the
resistance (R) of the windings. Variable losses are proportional to motor current (I) squared and
2
often are called I R losses.
The graph on Page 10 shows how motor losses (and efficiency) vary with load for a typical 50 hp
energy efficient motor. Fixed losses (core, friction and windage) have a greater effect in lightly
loaded conditions; I2R losses dominate as the load increases.
Importantly, increased core losses are not the only, nor necessarily the main reason that motor
losses sometimes increase due to poor repair practices. Studies have shown that motor efficiency
can decrease in rewound motors even if core losses actually decrease or increase only marginally.
Improper bearing replacements, for example, can increase friction and windage losses, and substituting smaller wire sizes for those used in the original winding can increase I2R losses [11].
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Likewise, procedures that change losses in one area can alter motor performance in another. Increasing the air gap by machining the rotor, for example, will reduce stray load losses but also will
increase magnetizing current and therefore increase winding losses while lowering the power factor.
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Motor Loss Distribution

(50 hp, 1800 rpm, TEFC)
4.0
1.0
Friction & Windage Losses

Stator Core Losses
50%
75%
100%
Fixed
Losses
Losses (kW)
Rotor Losses
2.0
0.0
25%
Variable Losses
Stray Load Losses
3.0
125%
% of Full-Load
The Cost of Poor Repair Practices

It is clear that poor repair practices may increase motor losses and reduce the energy efficiency of
repaired motors. The economic significance of this change will depend upon the size of the motor,
how much it is used, and local utility rates.
As an example, if a 100 hp motor runs 3,000 hours per year (about average) and electricity costs
$0.05 per kWh, a decrease in efficiency of 1% would increase the power bill by about $111 for the
year. If the motor is used more or utility rates are higher, the additional cost for electricity would be
higher. For instance, if it runs 8,000
hours per year and utility rates are $.09
Effect of 1% Decrease in
per kWh, a decrease in efficiency of 1%
Energy Efficiency
would add about $44 per month to the
electric bill, or around $528 annually.
8000 Hours
@ $0.09/kWh
Adds $111/Year
To Power Bill
Adds $528/Year
To Power Bill
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10
3000 Hours
@ $0.05/kWh
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Because repair procedures and materials

can affect motor losses and operating
efficiency, they should be carefully monitored and controlled. Check with the
service center that will do the work to be
sure they are familiar with recommendations in EASA Tech Notes 16 & 17 and use
the following procedures.
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Rewind Procedures That Maintain Motor Efficiency

Motor Loss
Increased By
Stator Core Losses
Overheating core steel during stripping

Damaging core insulation during
winding removal
Excessive abrasion or grinding
during core cleaning
Friction And
Windage Losses
Bearings and/or cooling fan not replaced

to original manufacturers specifications
Incorrect bearing fits
Incorrect bearing preload
Under/over fill of lubricant

Reducing conductor cross-sectional area

Changing the number of turns
Using incorrect winding configuration
Suggestions To Control
Or Quantify Loss
Conduct loop or core loss test before
and after winding removal
Follow procedures in EASA
Tech Notes 16 & 17
Calibrated oven temperature control
No-load test with three-phase wattmeter
No-load test at rated voltage with
three-phase wattmeter
Correct bearing fits and tolerances
(from ABMA Standards)
Use correct lubrication
Use correct type of seals
Follow manufacturers recommendations
Accurately record winding data and
verify with manufacturers data or EASA
Rewind Data
Machining rotor
Perform winding resistance tests

with milliohmmeter
Rotor Losses
Altering rotor bars and end rings
Repair to original specifications
Changing cage design
Balance rotor
Stray Load Losses
Change in air gap symmetry and

air gap eccentricities
Make sure shaft is straight and check

end shields for wear; repair or replace
defective parts
Bent motor shaft or damaged

end shields
Perform final vibration analysis
Specifying A Motor Rewind

Efficiency changes identified in most studies result from increased motor losses that are linked to inadequate quality control measures during repair or rewindinge.g., shortcuts, errors, and substitutions
of parts and materials [12]. When buying motor repair and rewind services, make sure all work will
meet expectations by providing written repair/rewind specifications for each motor. Service centers
also find this helpful and usually can do a better job if they know exactly what the customer wants.
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What should a repair or rewind specification include? Although it may be patterned after EASAs
Recommended Practice or other published motor repair and rewinding guidelines, its purpose is to
communicate the customers repair requirements and expectations to the service center. At a minimum, it also should require the repair to be performed by qualified, properly trained personnel in a
facility that is adequately equipped to handle the size and type of motor to be repaired.
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11
Additionally, a good repair specification should incorporate procedures that will ensure reliability
and help maintain the efficiency of the repaired equipment. EASA Tech Notes 16 & 17 provide a series of recommended practices to assure that these goals will be met. Some of the most important
ones are shown in the chart Rewind Procedures That Maintain Energy Efficiency on Page 11.
EASA also is continuing to work with service centers, the DOE, utilities, and independent laboratories to
identify other best practices and to educate both service centers and end-users of their importance.
Basic Repair Specifications. Every repair specification should include these procedures:
Inspect and test for mechanical and electrical defects.
Make and insert new coils.
Perform surge comparison test on new coils.
Dismantle and test stator and rotor as appropriate (e.g., continuity, insulation
resistance, high potential, surge comparison, loop or core loss, and growler tests).
Connect coils and leads; test all windings.
Test thermal protectors and similar devices;

replace if necessary.
Determine cause of failure.
Provide repair estimate and consult with

customer regarding repair/replace options.
Impregnate stator windings with insulating

varnish and cure in baking oven.
Install new bearings and seals of proper

size and type.
Check winding data against manufacturers

original data or EASAs Motor Rewind Data,
making corrections if necessary.
Assemble the motor, perform final tests

(including high-potential test), and paint.
Remove old windings and clean stator.
Report cause of failure, results of key tests,

and measurements.
Repeat loop or core loss test.
Install new insulation.
Document all additional services and specifications for quality assurance.
Note: More information about the various steps involved in repairing/rewinding motors is provided in the Appendix.
Repair Options. Many rewind specifications also request input from the service center
about repair options that could increase reliability or maximize the efficiency of the motor. These
might include:
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Providing a higher temperature insulation

system (typically Class H).
Repairing previous core damage by insulating and restacking the core or by other
methods.
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Making the new coils from wire having

greater cross-sectional area, if this can be
done without reducing the number of turns.
Optimizing motor efficiency by redesigning
the winding to match constant, nonstandard
plant voltage conditions.
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Identifying and correcting poor mechanical

repairs or incorrect bearing sizes or types.
Repairing other mechanical problems (e.g.,
restoring the shaft or housing surface, boring and bushing the end-brackets, or
correcting a soft foot condition).
Analyzing the pattern of failures and

the application to identify and correct
unfavorable operating conditions; may
require redesigning the motor or replacing it with one that is better suited
to the application.
Additional Services That Are Often Required Or Specified

To assure maximum life for motors that operate in harsh environments or unusual service conditions, rewind specifications may require additional repair services. These may include:
Additional Services
Mechanical modifications
High-temperature bearings and
grease
Electrical redesign
Insulation upgrade
Multiple dip-and-bake varnish cycles

Vacuum pressure impregnation (VPI)
Epoxy treatment
Dynamic balance
Dynamometer test
Note that some of these services may be part of a service centers basic repaire.g., upgraded insulation system or dynamic balance. Discuss the value and benefits of such
services with your service center.
Evaluating And Selecting

A Motor Service Center
When evaluating and selecting a motor service center, consider the firms business reputation and
professionalism, as well as its experience, reliability, responsiveness and past performance. Request
a list of customers and call them for their opinions. Perhaps most importantly, visit prospective service centers and ask questions.
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Knowledge and experience. Do their personnel have the required knowledge, experience and training? Are they abreast of industry developments? Do they use the latest technologies?
How do they verify winding data? If necessary, can they access outside engineering consulting services and databases?
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Equipment. The types and quality of equipment may vary widely from one service center to
another. Make sure the equipment is appropriate for the range of motor sizes to be rebuilt, and that
it is used properly. Test instruments and equipment, for instance, should have the capabilities and
accuracy required for the size of motor being repaired. Test instruments should also be calibrated at
least annually.
Other services. Do they routinely determine the cause of failures to help prevent recurrence? Can they help with repair/replace decisions and supply new replacement motors? Do they
offer preventive/predictive maintenance services or motor system application assistance? Can they
redesign motors for new applications or to maximize energy efficiency? Is their work backed by
a written warranty like the EASA Limited Warranties? Are they a factory-authorized service center for
one or more motor manufacturers?
Some Specific Items To Consider When

Evaluating A Motor Repair Facility
Electrical repair capabilities
Mechanical repair and machining

capabilities
Adherence to EASAs Recommended

Practice or other published repair standards
Documentation
Quality assurance measures
Communications
Housekeeping and safety
Current financial stability and future

prospects
Liability insurance and workers

compensation coverage
Technical capabilities and backup
Test facilities and test equipment

capabilities
Accuracy of test instruments
Availability of field assistance
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Lifting capacityi.e., crane and hoist

capacities
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Obtaining Motor Repairs

Of The Highest Quality
Follow these steps to find a service center that can consistently provide motor repairs and rewinding
services of the highest quality.
To Obtain The Highest Quality

Repairs And Rewinding Services
Ask EASA for a list of area service
centers.
Prequalify and select a motor service
center that can:
Assist in failure assessment.
Recommend whether to repair or replace the motor.
Provide new replacement motors, if
thats the best option.
Consistently deliver quality motor
repairs.
Support motor maintenance.
Establish a motor inventory system to

track the maintenance and repair history
of each motor. (MotorMaster software
available from the U.S. Department of
Energy and Motor Challenge Allied Partners can be helpful here, as can many
sales and service centers.)
Learn more about motor repair and

maintenance.
Work with an EASA service center or

other vendor to develop motor rebuilding specifications that meet your needs.
(EASAs Recommended Practice is a
good place to start.) Require conformance to those specifications by
inspecting new and rebuilt motors when
they are received.
Develop a motor repair/replace policy to

use when motors fail.
Require a detailed repair report for each

repaired motor.
How Service Centers Can Assure Quality Repairs

Service centers that implement quality assurance programs can consistently deliver reliable motor
repairs that maintain motor efficiency and reduce rework. By documenting quality procedures, such
service centers say what they do and do what they say for quality.
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Formalized quality assurance programs like the EASA-Q Quality Management System and ISO 90001994 can also verify stated quality through internal and third-party audits. Programs like these
require less effort on your part to ensure consistent quality in repaired motors.
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EASAs Quality Initiatives

This booklet was produced by the Electrical Apparatus Service Association (EASA) in cooperation
with the U.S. Department of Energys Motor Challenge Program as one of EASAs quality initiatives.
EASA service centers provide Reliable Solutions Today that will help you get the longest life and
most efficient operation from your electric motors.
EASA also has developed the EASA-Q Quality Management System for electrical apparatus service
centers. EASA-Q is a comprehensive guide for developing a quality system that exceeds all requirements for ISO 9000-1994 while presenting a recognized level of quality management in the motor
repair industry.
EASA-Q is written specifically for the motor repair industry to provide you with the best service
quality available in the industry.
Steps To Quality Management

Quality Inspection
"Say what you do."
Product Control
Procedures
Process Control
Procedures
Quality Control
"Do what you say."
Quality System Manual

Employee Training
Verification Testing
Equipment Calibration
Quality Assurance
"Show it through
documentation."
Customer Satisfaction
Employee Participation
Continuous Process
Improvement
Total Quality Management
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"Verify it through
independent audits."
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About EASA
EASA is an international trade organization of electromechanical sales and service firms throughout
the world. Through its many engineering and educational programs and publications, EASA provides members with a means of keeping up to date on materials, equipment, and state-of-the-art
technology.
When it comes to sales, application, service and maintenance of motors, generators, drives, controls
and other electromechanical equipment, look to EASA and EASA members for Reliable Solutions
Today. EASA members have the experience and professionalism to provide energy-efficient solutions for your complete motor system. To be assured of quality workmanship and performance,
always look for the EASA logo.
Comments or questions about this publication may be directed to the Electrical Apparatus Service
Association, Inc. at 1331 Baur Blvd., St. Louis, MO 63132 U.S.A., or e-mailed to [email protected].
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Appendix: Motor Repair Procedures

The following overview summarizes what happens during a typical motor repairi.e., stator rewind
that requires no mechanical repair. It also explains the effects that poor repair and rewinding procedures can have on motor efficiency and reliability.
Stator Core
Slot and Copper
Windings
Fan
Rotor
Laminations
Stator
Laminations
Air Gap
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End Ring
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Bearings
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Incoming Inspection & Testing. When the motor arrives at the service center, it is
carefully inspected for mechanical defects. This includes evaluating the general condition of the
frame, end shields, and bearings, as well as the exposed shaft and keyway. Any cracked, defective or
worn parts are noted on the job card or data sheet, along with nameplate data and important physical details (e.g., lead length and conduit box orientation). This information will ensure that the
motor can be reassembled in its original configuration.
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If the cause of failure is not apparent, the motor may undergo a number of electrical tests to diagnose the problem and determine the kinds of repairs needed. These may include continuity,
single-phase, and insulation resistance tests.
If the shaft turns freely and the motor is operational, a no-load test may be run at rated voltage and
frequency. Any unusual noises, vibrations or significant deviations from synchronous speed at nameplate voltage are noted on the data sheet.
POLYPHASE AC WINDING
HP
KW
RPM
POLES
DATE
MANUFACTURER
VOLTS
SLOTS
TYPE
COILS
MODEL
GROUPING
STYLE
TURNS/COIL
AUX. DEVICE
EFF.
HERTZ
WIRE SIZE
LEAD LENGTH
# LDS
FRAME
WIRES IN MULT.
C RISE
DUTY
PITCH:
SERIAL #
1 TO
CONNECTION
JUMPER
DP
AMPS
PHASE
C AMB.
INS. CLS.
TEFC
XPRF
TENV
SVC. FTR.
COIL
CORE LENGTH
CORE I. D.
BACKIRON
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JOB NUMBER
RV
LBS. WIRE
IC
(Please return copy to EASA Headquarters, 1331 Baur Blvd., St. Louis, MO 63132)
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Dismantling & Inspection. As the

motor is dismantled, it is examined for any internal mechanical or electrical defectse.g.,
signs of wear, rubbing or abrasion, mechanical
stress, thermal aging, loose connections, contamination, or arcing. Any defects are recorded
on the data sheet so that a detailed repair estimate can be prepared.
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Additional electrical tests, performed on the

stator windings as appropriate, may include
continuity, insulation resistance, high potential,
and surge comparison tests. The rotor is also checked carefully for cracked or broken bars, tested
using growler, and cleaned thoroughly. Test results are recorded on the data sheet, together with
important mechanical dimensions and measurementse.g., bearing sizes and fits and shaft run-out.
Each part is also positively identified to ensure control throughout the repair process.
CUSTOMER
Note: If moisture is detected but the stator windings are otherwise undamaged, they often can be
reconditioned without rewinding the stator.
Core Processing. If the motor is to be rewound,
the old winding must be removed and the stator core
must be thoroughly cleaned. First, however, the core
dimensions are measured and recorded so that new
slot insulation can be fabricated. The length of the
coil extensions is also measured and recorded.
Typical stator with

windings removed
At this point an initial loop test or core loss test

should be performed to check the condition of the
interlaminar insulation for shorts or other damage.
Any suspected problems are noted on the data
sheet to be checked or repaired after the winding
has been removed.
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In order to remove the old winding, the stator core

must be processed using acceptable practices that will not
damage it. For example, if a controlled-temperature oven is
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used, the temperature of the core must be monitored closely. Allowing it to get too hot could damage the interlaminar insulation, degrading its electrical and magnetic properties [13].
As the winding is being removed winding details are accurately recorded. These include the size
and shape of the coils, the wire size(s), the number of conductors, the number of turns, the coil groupings, and the connection pattern.
To assure that the new winding will be identical to the original, the data is checked for accuracy
against the manufacturers design specifications or a database like EASAs Motor Rewind Data. Reverse engineering techniques and computer programs may also be used to verify the accuracy of
winding data.
Next, the stator core is cleaned thoroughly, examined for evidence of shorts between laminations or electrical arcing and, if necessary, repaired. A second loop test or core loss test should then be performed
to ensure that the core is in good condition before the new insulation and winding are installed.
Winding. Accurate winding data and precise manufacturing techniques are used to produce
exact duplicates of the original coilsi.e., the same dimensions, wire size(s), number of turns, and
cross-sectional area. The new coils and appropriate insulation are then inserted into the stator slots.
Next, the electrical connections are made, after which the winding
is tested. Insulation resistance and surge comparison tests are
Typical stator with
commonly performed at this stage. For added stability, the
new windings installed
end turns of the winding usually are laced together.
Insulating Varnish. The rewound stator is
now impregnated with an insulating varnish and
placed in a low-temperature curing oven. Depending upon the repair specifications and the
application, some service centers use a vacuum pressure impregnation (VPI) or a trickle process instead
of a dip tank to saturate the windings with varnish.
Excess varnish is carefully removed from the stator bore
and mechanical mating surfaces. (Depending upon
the method used, the entire process is usually
repeated.)
Reassembly & Final Testing. The motor is then
reassembled with new bearings of the original size and type. This is important because using the wrong type
of bearings can affect motor efficiency. Bearings should also be installed carefully in accordance with recommended fits and tolerances as specified in the American Bearing Manufacturers Association Standards [14].
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The assembled motor is now tested as specified in EASAs Recommended Practice or other written
repair specifications. Tests may include surge comparison, high potential and no-load tests, as well
as any performance tests required by the customer. After being inspected a final time, the motor is
painted and prepared for shipping.
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References
[1] MotorMaster (U.S. Department of Energy, 1998).
[2] How To Get The Most From Your Electric Motors (Electrical Apparatus Service Association,
Inc., St. Louis, MO, 1997).
[3] Olav Vaag Thorsen and Magnus Dalva, A Survey Of Faults On Induction Motors In Offshore
Oil Industry, Petrochemical Industry, Gas Terminals, And Oil Refineries, IEEE Transactions On
Industry Applications, Vol. 31, No. 5, (September/October 1995).
[4] EASA AR100-1998 Recommended Practice For The Repair Of Electrical Apparatus (Electrical
Apparatus Service Association, Inc., St. Louis, MO, 1998).
[5] EASA Limited Warranties (Electrical Apparatus Service Association, Inc., St. Louis, MO, 1986).
[6] Andr Charette and Pierre Anger, Effects Of Repair On Electric Motor Efficiency (Hydro
Quebecs LTEE Laboratory, Quebec, August 1995).
[7] Tech Note 16: Guidelines For Maintaining Motor Efficiency During Rebuilding (Electrical
Apparatus Service Association, Inc., St. Louis, MO, May 1992); Tech Note 17: Stator Core
Testing (Electrical Apparatus Service Association, Inc., St. Louis, MO, October 1992).
[8] Austin H. Bonnett, Understanding The Changing Requirements And Opportunities For Improvement Of Operating Efficiency Of AC Motors, IEEE Transactions On Industry Applications,
Vol. 29, No. 3, (May/June 1993).
[9] Vince Schueler and Johnny Douglass, Quality Electric Motor Repair: A Guide Book For Electric
Utilities (Washington State Energy Office, Olympia, WA, August 1995).
[10] NEMA Standards MG 10-1994, Table 2-2 (National Electrical Manufacturers Association,
Rosslyn, VA, 1994).
[11] Vince Schueler, Paul Leistner and Johnny Douglass, Industrial Motor Repair In The United
States (Washington State Energy Office, Olympia, WA, November 1995).
[12] Quality Electric Motor Repair; and Markus Zeller, Rewound High-Efficiency Motor Performance
(B.C. Hydro - Power Smart, Vancouver, BC, August 1992).
[13] Core Iron Study (Electrical Apparatus Service Association, Inc., St. Louis, MO, 1984); and
Quality Electric Motor Repair.
[14] ABMA Standard 7 and ABMA Standard 20 (American Bearing Manufacturers Association, Inc.,
Washington, DC, 1987 and 1988).
Disclaimer
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The information in this booklet was carefully prepared and is believed to be correct, but EASA
makes no warranties respecting it and disclaims any responsibility or liability of any kind for any loss
or damage as a consequence of anyones use of or reliance upon such information.
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Notes
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What are some reasons why motors fail?

What are some reasons why motors fail?

What factors should be considered when deciding whether to repair or replace a failed motor?

What factors should be considered when deciding whether to repair or replace a failed motor?

L APPA

A Guide To AC Motor Repair And Replacement

Prepared by Electrical Apparatus Service Association, Inc. in cooperation

Reliable Solutions Today!

A Guide To AC Motor Repair And Replacement

The booklet focuses on the workhorses of industry1 to

Reliable Solutions Today!

A Guide To AC Motor Repair And Replacement

Why Motors Fail

Recommended Maintenance Procedures [2]

Identify and correct excessive vibration.

Clean accumulated dust and dirt from

Detect and dry moisture in the

Reliable Solutions Today!

Install properly sized overload

A Guide To AC Motor Repair And Replacement

Even with regular maintenance, motors eventually

Making The Decision To

Reliable Solutions Today!

A Guide To AC Motor Repair And Replacement

Reliable Solutions Today!

A Guide To AC Motor Repair And Replacement

Reliable Solutions Today!

A Guide To AC Motor Repair And Replacement

Be Proactive. As mentioned throughout this booklet, it makes sense to know as much as

Calculating Energy Cost Savings

Energy Cost Saving*

Demand Cost Saving

Savings in dollars per year

Horsepower rating of the specified load

Energy costs in dollars per kilowatt hour

Running time in hours per year (how long

average motor efficiency from 1994i.e.,

Monthly demand charge

Number of months per year demand charge

Reliable Solutions Today!

A Guide To AC Motor Repair And Replacement

Calculating Simple Payback

Simple paybacki.e., number of years required to

New motor cost

Rewind/repair cost (from quote or Vaughens Price

Utility rebate (if available)

Energy charge reduction (from Energy Cost Saving

Demand charge savings (from Demand Cost Saving

Reference: NEMA MG 1, Table 12-10.

Reevaluate each motor and application

Reliable Solutions Today!

A Guide To AC Motor Repair And Replacement

Importance of having the motor back in

Simple payback analysis.

Cost and availability of repair service as

Type and size of motor (e.g., hp, efficiency

Age and repair history of the motor.

Application (speed/torque requirements).

Maintenance and capital budgets.