How to Decide Whether to Repair or Replace Your Electric Motor
When a motor fails unexpectedly, causing downtime, it’s crucial to quickly assess whether repair or replacement is the best course of action. Several factors, such as cost, part availability, and the impact of downtime on your business, should guide this decision. In this article, we’ll explore the key considerations that will help you make the right choice.
Identify the Cause of the Failure
Before deciding whether to repair or replace the motor, you must first determine what caused the failure. If the issue stems from your driven application or a lack of routine maintenance, you can address these problems internally to prevent future breakdowns. However, if the failure resulted from a manufacturing defect, it’s essential to inform your motor shop so that corrective measures can be taken.
Key Considerations
To make the best decision, consider the following questions:
- Does the motor properly fit your application?
- Has a catastrophic failure occurred?
- For instance, is there damage to critical components like the stator core, laminations, windings, rotor core, rotor bars, rotor end rings, shaft, bearings, or end brackets?
- Will purchasing a new motor lead to extended downtime?
- What is the overall condition of internal and external parts?
- How old is the motor?
- What are the repair costs versus replacement costs over time?
- Is the motor an EPAct or NEMA premium model?
- Are any other parts severely damaged?
When to Repair
If the answers to these questions indicate the following, repairing your motor might be the best option:
- The motor is still the best fit for your application.
- No catastrophic failure has occurred.
- Replacing the motor would result in significant downtime.
- The motor is in generally good condition.
- The motor is relatively new.
- Repair costs are lower than replacement costs over time.
- It’s an EPAct or NEMA premium motor.
- Only the failed part is damaged, with no severe damage to other components.
If you’re unsure about the answers, it’s vital to have a strong relationship with your motor repair shop. Getting an honest estimate for repair versus replacement from a trusted service provider can help you make the right decision for your specific needs.
When to Replace
If your situation aligns with the following points, replacing the motor may be the better choice:
- The motor is no longer the best fit for your application.
- A catastrophic failure has occurred.
- Replacing the motor will not cause excessive downtime.
- The motor’s overall condition is poor.
- The motor is old.
- Repair costs are higher than replacement costs over time.
- The motor is not an EPAct or NEMA premium model.
- Several parts are severely damaged.
Energy, Efficiency, and Life Cycle Costs
To further guide your decision, calculate the annual energy costs, life cycle costs, and efficiency of your current motor compared to a potential replacement.
- Annual Energy Cost Calculation: This will help determine how much energy your motor consumes annually, assuming it runs at 100% load.
- Life Cycle Cost Calculation: This accounts for the total cost of owning and operating the motor over its lifespan.
- Efficiency Calculation: Compare the efficiency of your existing motor with that of a new motor to see if an upgrade would offer significant benefits.
Final Considerations
If you decide to replace your motor, ensure the new motor offers superior performance compared to your old one. There’s no point in investing in a replacement unless it improves your system’s overall efficiency and reliability. Evaluate all performance metrics carefully before making your final decision.
