Synchronous motor repair at SPEC SERWIS is a specialist service aimed at industrial plants, sorting centres, waste management facilities, the food industry and intralogistics, where downtime is particularly costly. We focus on restoring synchronous drives to working order quickly, while at the same time looking for the causes of the failure in order to minimise the risk of it recurring.
Synchronous motor repair – a comprehensive approach
Synchronous motors are used wherever stable speed, high efficiency and precise cooperation with frequency inverters matter. Repairing them requires experience in mechanics, electrical engineering and drive electronics alike.
As part of the synchronous motor repair service we offer, among other things:
- full preliminary fault diagnosis (electrical measurements, insulation tests, vibration tests, checking of windings, bearings and the cooling system),
- mechanical and electrical repairs, including replacement of bearings, reconditioning or replacement of shafts and housings, repairs to windings, connections and sensors,
- verification of correct cooperation between the motor and the frequency inverter or motor starter, including adjustment of the settings.
We work so that after the repair the motor not only "starts up", but runs stably, in line with the manufacturer's recommendations and the requirements of the specific production line.
What does the synchronous motor repair process look like?
We start every case with a diagnosis in which we analyse both the condition of the motor and its operating conditions (load, environment, starting method). A typical repair process includes:
- Inspection and preliminary tests – identification of symptoms (noise, vibration, overheating, starting problems, tripping of protective devices).
- Electrical measurements – checking the windings, insulation, connections, sensors and protective elements.
- Disassembly and mechanical inspection – assessment of the condition of the bearings, shaft, seals, housing, fans and terminals.
- The actual repair – replacement or reconditioning of damaged components, possible winding work (repairs or rewinding in specialist workshops).
- Assembly and final tests – bench tests or tests under load at the customer's plant, checking temperatures, vibration, current and torque.
At every stage we document the work carried out and give the customer clear information about the scope of the repair and the expected time to restore the unit to working order.
Repair or replacement? Technical advice and costs
Not every failure has to end with replacing the motor with a new one. In many cases, repairing a synchronous motor is the more cost-effective solution, especially when:
- the unit is integrated with a non-standard gear unit or application,
- the delivery time for a new drive is long,
- the motor operates at a critical point in the production process.
Based on the diagnosis, we prepare for the customer a clear repair quotation together with an assessment of its cost-effectiveness compared with purchasing a new unit. We can also propose a modernisation, e.g. replacement with a motor of a higher efficiency class or adapting it to work with a new frequency inverter.
Safety, testing and warranty after the repair
A synchronous motor undergoes functional tests after the repair – reproducing the real operating conditions as far as possible. We check, among other things:
- speed stability,
- the level of vibration and noise,
- the operating temperature at the given load,
- the correct operation of protective devices and sensors.
We attach documentation to the repairs carried out (scope of work, replaced parts, measurement results). We provide a limited warranty for the services performed, the terms of which are adapted to the type of repair and the drive's operating conditions.
FAQs – synchronous motor repair
Below we have gathered answers to the most frequently asked questions about synchronous motor repair. They will help you plan service activities and reduce the risk of unnecessary downtime.
What symptoms indicate that a synchronous motor needs repair, not just a check?
Typical symptoms indicating the need for repair include: a marked increase in noise and vibration, excessive heating of the motor, starting problems (jerking, loss of synchronisation), frequent tripping of overcurrent protection, and traces of grease leaks or mechanical damage. If such symptoms keep recurring, a regular check alone will usually not be enough – a full diagnosis and repair is needed.
Is repairing a synchronous motor always worthwhile?
Not always. During the diagnosis we assess the scale of the damage and estimate the costs and repair time. If it turns out that the cost of reconditioning is close to the price of a new motor, or the predicted risk of further failures is high, we recommend replacing the unit. The decision rests with the customer, but we always present the options with a technical and economic justification.
Is it possible to repair a synchronous motor on site, without disassembly?
The scope of work that can be carried out on site depends on the type of fault. On site it is possible to carry out a full diagnosis, some adjustment work, replacement of certain components and corrections to the settings of the frequency inverter or motor starter. In the case of serious mechanical or winding damage, disassembly of the motor and repair in workshop conditions is necessary.
How do you prepare a synchronous motor for shipment for repair?
Before shipment, disconnect the power supply, secure the cables, disassemble the motor in accordance with the manufacturer's documentation and mark its position relative to the gear unit or machine to make later installation easier. It is also important to secure the unit solidly on a pallet or in a transport crate so as to avoid mechanical damage during transport. However, we suggest leaving such shipments to professionals with experience in transporting this type of equipment. We can organise transport on the customer's behalf.