Discover why motor coils burn, common causes, and practical fixes. Learn how to prevent motor coil failure and save on costly repairs with these expert tips
Why Does Motor Coil Burn? Major Causes And Fixes
Introduction:
Nowadays, motors are used in every home, factory or office. But often people face a common problem – motor coil burning. Whenever the motor coil burns, not only the work stops but there is also extra expense of repair or replacement. But do you know what are the main reasons for motor coil burning? And how can you avoid this problem? In this article, we will discuss in detail the major causes of motor coil burning, their solutions, and some expert tips. So let’s start!
What is Motor Coil Burn?
Motor coil burn is basically a condition when the copper winding inside the motor overheats and burns. A burnt coil means the motor needs to be repaired or the winding motor coil burn occurs when the copper winding inside the electric motor gets overheated and essentially motor coils burns out.
Main Reasons for Motor Coil Burn.
1. Overloading Motor Coils Burn
The most common reason is overloading. When the motor is loaded beyond its capacity, extra current flows in the winding, due to which the coil can get heated and burn.
Example: If you have a 1 hp motor and you are using it for 2 hp work, then the coil will get overloaded.
2. Voltage Fluctuation
Low or high voltage is also a major reason for motor coil burn. When the voltage is very low, the motor draws more current, and at high voltage the insulation can be damaged.
3. Poor quality wiring
If low quality copper or aluminium wire is used in the motor winding, it heats up quickly and may burn.
4. Lack of Maintenance
Regular maintenance should be done, otherwise dust and moisture get deposited on the winding, which generates heat, and the coil can burn.
5. Single Phasing
In 3-phase motors, if one phase is running (single phasing), then uneven load comes on the winding of the motor, which can cause coil burn.
6. Short Circuit
If the insulation inside the winding becomes weak or the wire touches it, a short circuit can occur, due to which the coil can catch fire immediately.
7. Poor Ventilation
If there is no proper ventilation around the motor, then heat does not dissipate and the coil may overheat and motor coils burn.
8. Water Ingress
If water enters the motor (as happens in borewell motors), the winding may get shorted and the coil may burn.
How to Identify Motor Coil Burn?
- Smell coming from the motor (Motor Coils Burn)
- Motor not working or slowing down
- Circuit breaker tripping
- Smoke coming from the motor
- Unusual noise
If you see any of these signs, immediately stop the motor and get it checked.
What to Do If Motor Coil Burns?
- Switch off the motor immediately.
- Disconnect the power supply.
- Call an expert electrician or motor rewinding specialist.
- Get the burnt coil replaced or rewinded.
- Proper testing of the motor
How to Prevent Motor Coil Burn?
- Maintain proper load.
Always run the motor at its rated capacity. Do not overload it.
- Use voltage stabilizer
If there is voltage fluctuation in your area then get a stabilizer or automatic voltage regulator installed.
- Regular Maintenance
Get the motor service done every 3-6 months. Keep cleaning dust, grease, or moisture.
- Use quality wiring
Always use high quality copper winding or wire. Avoid local or duplicate wire.
- Proper Ventilation
Install the motor in a place where air can easily pass. Avoid overheating.
- Save yourself from water
If the motor is in an open area or borewell, protect it with a waterproof cover.
- Install protection devices
Install overload relay, MCB, fuse, or thermal protector so that the motor automatically shuts down in case of overload or short circuit.
How is Motor Coil Burn Repaired?
- Opening the motor
- Removing the burnt winding
- Installing new winding (rewinding)
- Checking the insulation
- Reassembling the motor
- Testing
Motor Coils Burn, get this work done only by an expert technician as proper winding technique and insulation is very important.
Cost of Motor Coil Burn Repair?
- Small motors (0.5-2 HP): ₹500 – ₹2000
- Medium motors (2-5 HP): ₹2000 – ₹5000
- Large motors (5 HP+): above ₹5000
Cost depends on motor size, winding material, and labor charges.
Ask People Also Questions
| Which parts should be checked when the motor coil burns? |
| Answer: First of all check the winding, then also check the insulation, bearings, and wiring terminals. Sometimes the overload relay or MCB should also be checked, as these can also get damaged. |
| Does the coil burn if cheap winding wire is used? |
| Answer: Yes, the risk of the coil burning increases a lot if cheap or duplicate winding wire is used. Low quality wire heats up quickly and the insulation is also weak. Always use branded and high quality copper wire. |
| Is it right to get the motor coil rewinded if it burns or to buy a new motor? |
| Answer: If the motor is not old and other parts are fine, then it is right to get it rewinded. But if the motor is very old or the coil is burning repeatedly, then buying a new motor is a better option. |
| What can be done at home to prevent the motor coil from burning? |
| Answer: Do not overload the motor, do regular maintenance, and use voltage stabilizer. Keep the surroundings of the motor clean and avoid water. Protection devices like MCB or overload relay can also be installed. |
| Why does the motor coil burn repeatedly? |
| Answer: The main reason for the motor coil burning repeatedly is overloading, low quality winding wire, or voltage fluctuation. If you make the motor work more than its capacity or the wiring is not correct, then the chances of the coil burning increase. So always use quality wire and avoid overloading. |
Expert Tips – To avoid motor coil burning (Pro Tips)
Always get the wiring and installation work done by a reliable electrician.
Protect motor from direct sunlight and water.
Keep testing the motor regularly.
Overload relay or thermal protector is a must
Conclusion
The burn of the motor coil is one of the most common motor coil problems everyone experiences. Always use quality products; do not overload and seek expert advice; if you feel that your motor coil has burnt, immediately seek expert help. Following the tips and solutions given in this article will prolong the life of your motor and save you unnecessary expenses. The burn of the motor coil is one of the most common motor coil problems everyone experiences.
