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Monday morning, the cooling tower pump trips and the smell of burnt varnish comes out of the panel. On the maintenance manager's desk there are two options: a rewinding quote from the local repair shop and the store price of a new motor of the same rating. This article is meant to put those two documents side by side and help you ask the right questions. We do not give any figure for rewinding labour; that price varies from shop to shop, with the condition of the motor and the amount of copper. What we provide are the decision criteria and the real electric motor prices on the new-motor side.
Diagnosis First: Which Part of the Motor Has Failed?
“The motor burnt out” is usually an incomplete diagnosis. Before deciding, you need to know which part has failed, because the cost balance between rewinding and a new motor depends entirely on it. Have the repair shop or your own electrician carry out these checks:
- Insulation resistance (megger): Has the insulation between winding and frame deteriorated? A low reading may be caused by moisture; do not decide on rewinding before measuring again after drying.
- Phase winding resistances: Are the three phases close to each other? A clear difference points to an inter-turn short circuit.
- Bearing noise and shaft play: Does the shaft stick, grind or move axially when turned by hand?
- Terminal box: Sometimes a “burnt motor” is only a terminal block overheated by a loose connection.
If only the bearings are worn, the issue is bearing replacement, not rewinding, and a new motor is usually unnecessary. If the winding is burnt, that is where the real comparison begins.
Ask What the Rewinding Quote Includes
Looking only at the total of two quotes is misleading. Comparing with a new motor price before the scope of the rewinding quote is clear means comparing apples with oranges. Ask the shop these questions in writing:
- Are the bearings renewed, or are the old ones refitted?
- Is varnish impregnation and oven curing done after rewinding?
- Is a balance check of rotor and fan included?
- Are insulation and no-load current results provided in writing on delivery?
- Are removal, transport and reinstallation labour included?
- Does the shop give any assurance on the rewinding work, and what does it cover?
Each of these items is either in the quote or appears later as a separate invoice. Make the comparison with a “full-scope rewinding quote”.
The New-Motor Side: Sample Store Prices
The other side of the scale is clear. The table below shows six models at 1500 rpm, chosen from pump and fan ratings that fail frequently. You can find the model matching the power and speed on your motor's nameplate in the online store.
| Model | Power | Speed | Housing | IEC frame | Excl. VAT | Incl. VAT (20%) |
|---|---|---|---|---|---|---|
| DRG-90L-4 | 1.5 kW | 1500 rpm | Aluminium | 90L | 6,210.75 TRY | 7,452.90 TRY |
| DRG-112M-4 | 4 kW | 1500 rpm | Aluminium | 112M | 10,960.95 TRY | 13,153.14 TRY |
| DRG-132M-4 | 7.5 kW | 1500 rpm | Cast iron | 132M | 17,825.50 TRY | 21,390.60 TRY |
| DRG-160L-4 | 15 kW | 1500 rpm | Cast iron | 160L | 30,610.80 TRY | 36,732.96 TRY |
| DRG-225S-4 | 37 kW | 1500 rpm | Cast iron | 225S | 68,937.00 TRY | 82,724.40 TRY |
| DRG-280S-4 | 75 kW | 1500 rpm | Cast iron | 280S | 131,670.00 TRY | 158,004.00 TRY |
Prices are taken from the DRG Motor online store list dated 24.09.2026; a 3% discount applies to bank transfer/EFT payments, shipping is not included in the price and is paid by the buyer. Please check the store page for current prices.
The practical takeaway: at small ratings, the gap between a new motor and rewinding can be narrow; for a 1.5 kW motor, rewinding plus removal and transport can quickly approach the price of a new unit. From 37 kW upwards the price of a new motor rises markedly; at these ratings, rewinding a motor with a sound frame is often worth serious consideration.
Deciding with a Simple Ratio
If you have a full-scope rewinding quote and the excl. VAT price of the same new model, divide the rewinding amount by the new motor price. The resulting ratio answers the question “what share of a new motor's price am I paying to save the old one?”. For example, for the 7.5 kW cast iron DRG-132M-4 the new motor price excl. VAT is 17,825.50 TRY; simply divide your rewinding quote by this figure.
Each plant sets its own acceptable limit for the ratio. However, if the ratio is high in the following two cases, moving to a new motor makes sense:
- The motor has been rewound before (each rewinding is done on a motor whose lamination stack and insulation have aged).
- The nameplate is unreadable, the frame belongs to an old standard, or spare parts are unavailable.
If the ratio is low and this is the motor's first failure, rewinding is generally a reasonable option.
Downtime: The Cost Missing from the Quote
A motor sent for rewinding goes through dismantling, winding, varnishing, curing and testing at the shop. That time depends on the shop's workload, and your line stands still meanwhile. When a new motor is shipped from stock, the waiting time is order confirmation plus transport; shipping conditions are on the delivery and shipping page.
Calculate the cost of downtime yourself: find what one hour of stoppage of the line driven by that motor costs the business and multiply it by the waiting time the shop quotes. Added to the rewinding quote, this figure can turn the comparison into a completely different picture. Especially in plants where a single pump or fan stops the whole production, this item decides the matter.
Frame, Shaft and Bearing Seat Damage Changes the Math
A burnt winding is sometimes the result of a mechanical failure. If a bearing has collapsed and the rotor has rubbed the stator, the lamination stack may be damaged. Simply rewinding such a motor means facing the same failure again soon. If any of the following is found, ask the shop for a separate price:
- Wear or ovality in the bearing seat (requires a sleeve or machining).
- Bent shaft or widened keyway.
- Cracks in the frame foot or flange.
- Rub marks on the rotor and stator surfaces.
Once these jobs are added to the rewinding quote, the total can exceed the price of a new motor at most small and medium ratings.
Decision Table: Which Way in Which Case?
| Situation | Sensible direction |
|---|---|
| Bearing failure only, winding sound | Replace bearings; no new motor needed |
| Small rating, burnt winding, frame sound | Compare the rewinding quote with the new motor price as a ratio; if the gap is narrow, new motor |
| Large rating, first failure, frame and shaft sound | Full-scope rewinding deserves serious consideration |
| Rewound before, burnt again | New motor first |
| Shaft, bearing seat or frame damaged | Compare total repair with a new motor; usually new motor |
| Line cannot stop for long | Restart the line with a new motor, rewind the old one as a spare |
Mounting Compatibility When Switching to a New Motor
When a new motor is chosen, one that does not fit the machine creates a second expense. Photograph the old motor's nameplate and match: power (kW), speed, supply voltage, IEC frame number (shaft height), mounting type (foot-mounted B3, flange B5 or small flange B14), shaft diameter and key size. If the nameplate is worn off, measuring the shaft height and shaft diameter is the fastest way to find the right frame. You can use the calculators to compare torque and current.
The old motor does not have to be scrapped
The last row of the table is a method many maintenance teams prefer: the line is restarted immediately with a new motor, the failed one is rewound without haste and kept on the shelf as a spare. That way you will not face the same dilemma at the next failure.
Frequently Asked Questions
Does a rewound motor perform like a new one?
It depends on the quality of the rewinding and the condition of the lamination stack. With the correct wire cross-section and number of turns, varnished and tested, the motor does its job; with a damaged lamination stack the outcome is uncertain. Ask the shop for measurement results on delivery.
Can I get a rewinding price from DRG Motor?
Our role in this comparison is the new-motor side. We can tell you the price on the new-motor side and the model matching your nameplate; the rewinding amount must come from a repair shop in your area.
Is shipping included in the new motor price?
No. Store prices do not include shipping, which is paid by the buyer. A 3% discount applies to bank transfer/EFT payments; details are on the payment options page.
What should I buy to replace a motor with an unreadable nameplate?
Measure the shaft height, shaft diameter, flange dimensions and foot hole spacing and send them with photos; we will determine the right frame together.
Send us a photo of your failed motor's nameplate and we will tell you the new-motor equivalent and its price: +90 (542) 666 11 11 · [email protected] · Contact page.
