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Repair or Replace?

Motor Repair Pros and Cons

Determining whether to repair or replace a motor is a critical decision for facilities both small and large.  Decision makers must weigh the pros of replacement (improved efficiency, fewer breakdowns/production halts) versus the pros of repair (short-term cost savings).  

EISA does not require that non-compliant motors be put out of service, only that most new general purpose 1-200 hp motors produced and sold in the United States must meet NEMA Premium Efficiency standards.  This means motor repair may be a viable option in some situations, but it's important to understand the real cost of repairing lower-efficiency motors.  

  • For smaller motors, buying new costs less than rewinding
  • Larger premium efficiency motors offer fast payback when compared to rewinding costs
  • Rewinding typically results in an efficiency loss of 1%, which increases energy costs*
Standard Efficiency vs. NEMA Premium
  Standard NEMA Premium
Efficiency 92.5% 95.4%
Operating Cost $49,115 / year $47,622 / year
Annual Savings**   $1,493
10-Year Savings**   $14,930
EPACT vs. NEMA Premium
  EPAct NEMA Premium
Efficiency 94.5% 95.4%
Operating Cost $48,076 / year $47,622 / year
Annual Savings**   $454
10-Year Savings**   $4,540

*According to the BC Hydro and Ontario Hydro Studies.

**This is based on $.10/kwh, so if energy costs are higher in your area, your savings will be greater.

Motor Repair Guide

Repair or Replace Decision Chart


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