Beatson Fan & Motors, based in Sheffield, offer a bespoke electric motor rewinds service near you.
- 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 rewinding service near you
- Small electric motor repair near you
Our Electric Motor Rewinding 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.
Unless the issue is evident immediately, it is likely that we will need to dismantle the motor to examine it fully. Our experienced team has 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 that 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 your motor. Alternatively, you’re more than welcome to pick up the motor from our shop yourself.
How to determine if your electric 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 them. 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.
Small Electric Motor Repair Near You
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 electric motor rewinding for our valued customers. Whether you’re based near our Sheffield workshop or are further afield, we’d be happy to assist you with any small electric motor repairs or other services that you may need.
Get in touch with a motor rewinding shop near you 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.
Check out our full overview of the electric motors and related services we offer.
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 it might need repairing.