Beatson
By Tom Beatson on 19th October 2020 (updated: 18th January 2021)

Beatson Fan & Motors, based in Sheffield, offer a bespoke electric motor rewinds service.

The business has been family-run in Sheffield since its inception. Our founder, Herbert Beatson, opened a handful of small workshops in a disused brewery in 1928, and the business has been handed down through three generations since then. Our current premises on Newhall Road is home to our entire operations; we keep all our stock here, in addition to performing all repairs and rewinds for our valued customers.

We offer:

  • Free local collection and delivery service for all motor rewinds
  • Free testing and quotation
  • 24-hour service if required
  • Full 12-Month Parts and Labour Guarantee

Electric motor rewinds

Our Motor Rewinds process

1. First Inspection

You’ll send us the motor, or if you’re local to us we’ll pick it up from you. We will then inspect your motor to determine what the issue is. We may ask you questions related to how often the motor is used, what kind of operating environment it is in, and whether you’ve had any rewinds performed before. This will help us determine the source of the issue so that we can select the right course of action.

2. Dismantling

Unless the issue is evident immediately, it is likely that we will need to dismantle the motor to examine it fully. Our experienced team have dismantled and re-assembled hundreds of motors, so your machine will be in safe hands. After this has been done we will be able to determine the source of the issue and be able to offer you a bespoke quote for the rewind or repair. We are not obliged to re-assemble items which have been dismantled for quotation purposes only.

3. Removal of Winding and Cleaning of Core

If you decide to go ahead with the motor rewind then our team will get on with the task of recording the winding detail on data sheets, before carrying out core loss testing and then removing the old winding. It’s important for the stator core to be properly cleaned at this point so that the motor is properly prepared for rewinding.

4. Rewinding the Motor

Once the motor has been properly prepped we’ll get on with the rewinding, ensuring that the original winding configuration is duplicated for optimal efficiency. In some cases, our engineers may be able to identify a different style of winding that will match the motor’s performance. Once the rewinding is completed, we’ll conduct a series of tests to ensure that all is performing as it should be, before re-assembling the motor.

5. Collection or Delivery

Once the job is completed we’ll happily arrange a free delivery (if you are local to us), or enlist a trusted courier service to deliver you motor. Alternatively, you’re more than welcome to pick up the motor from our shop yourself.

How to determine if your motor needs a rewind

1. Rule out obvious causes

To determine if your motor needs a rewind, it’s sensible to first rule out any obvious causes. Start by assessing the condition of your motor and make note of any physical defects that the motor has. Obvious issues could include broken mounts, scorch marks and contamination from water or rust. After you’ve made a preliminary inspection of the component then you can try rotating the shaft by hand. If you’re unable to move the fan, then an obstruction or failed bearings could be the issue, as opposed to a winding issue.

2. Testing Motor Windings

Once you’ve determined that the motor is not failing due to an obvious mechanical reason; measure winding resistance, check 3 phase windings by supplying low voltage and check the currents are balanced.

3. Measure insulation resistance

Insulation resistance (IR) is another measurement that you can use to determine if your motor is in need of a rewind or not. These measurements can be taken between windings, and between the windings and earth point. The IR value should preferably be greater than 100M ohms and a minimum of 2M ohms. A measurement of fewer than 2M ohms indicates that the insulation is deteriorating, or has failed already. Many winding faults can be attributed to low IR. Contamination, power surges, excessive heat, vibration or damaged wires can all contribute to creating a low IR. In some cases, a thorough clean and dry can help to fix these issues, but often an electric motor rewind is the most efficient route to resuming optimal performance.

How to rewind an electric motor

1. Clean work surface

Clean your work surface, making sure to get rid of any dust or debris that might have collected. Be extra sure of cleaning away any metal shavings, as the magnetic components of your electric rewind could attract these and cause problems when later down the line.

2. Dismantle Motor

Mark all removable parts. Take note of the position of pulleys, couplings etc. Check bearings housings and take not of bearing sizes (take into account nuts, bolts, washers, screws etc. and keep safe).

3. Take note of the Motor Windings

Check winding connections and make a drawing if necessary. Take note of the type of winding i.e. number of slots, coils and poles.

4. Remove Coil from Stator

Cut one end off the winding, making sure not to damage the stator. Pull the coil out from the end (heat may be required to soften the varnish that holds the coils in place).

5. Insulate Stator

Clean all the old insulation from the stator. Check the slots for sharp edges and remove. Re-insulate slots using correct thickness insulation.

6. Source Correct Replacement Wire

Source the same gauge of wire used in the original windings. Count the number of turns in the original winding coils.

7. Recreate Original Winding Coils

Wind a new set of coils in the correct size to recreate the original windings. Connect Coil lead ends as per original winding connections.

8. Varnish Windings

Perform Insulation test and continuity test on the windings, impregnate the windings with varnish and stove.

9. Reassemble Motor

Fit new bearings to the rotor. Insert the rotor back into the stator. Refit endplates, aligning all location indicators made whilst dismantling the motor. Test motor. Re-paint.

Get in touch today!

We offer a free local collection and delivery service for all motor repairs, as well as free testing and quotation, and a Full 12-Month Parts and Labour Guarantee.

Give us a call on 0114 204 4831 or send us a message using the form below if your motor is underperforming, or you think you it might need repairing.

Contact us

Got a question or want to tell us something?

Simply put your details and questions into the form below and we’ll get back to you as soon as possible.

You can also call our office on 0114 204 4831, we’re open Monday to Friday from 8am-4:30pm.

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FAQs

What is a motor rewind?

A motor wind is a necessary process that enables old or well-used motors to regain some or all of their efficiency. Over time, all motors are prone to lose the efficiency that they initially ran with. Whilst some may find it financially convenient to replace their old motors with new models, this might not be an option for others who rely on a piece of older machinery to aid their processes. A motor rewind performed by skilled, experienced tradesmen can rejuvenate older motors so that they can perform as efficiently as possible. Motor rewinds are often the most cost-effective solutions to servicing smaller motors and is the only service option for obsolete motors.

How do you rewind a single-phase motor?

Rewinding a single-phase motor requires skill and experience to do correctly. You will need to pay close attention to the winding pattern as these vary from one motor to the next.

How much does it cost to rewind an electric motor?

The cost of an electric motor rewind varies depending on the size of the motor, and the complexity of the winding pattern.

Can you fix a burnt-out electric motor?

A burnt-out electric motor can be fixed by way of a complete rewind. In some cases, it’s more prudent to replace a small motor than give it a rewind.>

Why does a motor need rewinding?

Motors need rewinding in order to regain their previous efficiency, or even to bring back failed motors so that they can give a few more years service. Motors that have burnt also benefit from rewinding to bring them back to working condition.

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