Replacing Industrial Motors

Industrial roller shutters typically use:

Single Phase Motors (240V)

• Suitable for lighter duty or lower usage
• Often used on smaller industrial doors

Three Phase Motors (415V)

• Designed for heavy-duty applications
• Suitable for large shutters or high-frequency use

Inboard Motors (Chain Driven)

• Mounted inside the endplates
• Use a chain to drive the barrel

Outboard Motors (Direct Drive)

• Mounted externally on the endplate
• Barrel passes directly through the motor

Understanding which type you have is essential before replacing.

Inboard Motors

• Chain driven system
• Lower initial cost
• More maintenance required

Outboard Motors

• Direct drive (no chain)
• More reliable and smoother operation
• Preferred for modern installations
  

In many cases, it is possible to upgrade or change an industrial roller shutter motor, but it is important to understand why you are upgrading and whether the rest of the door system is designed to accommodate the change. Simply fitting a larger or different motor does not always improve performance and can sometimes create operational or safety issues.

Upgrading to a Larger Motor

A larger motor is not usually required unless the existing motor has been incorrectly specified or the weight of the door has increased due to modifications. Industrial motors are carefully selected based on the curtain weight, axle size, duty cycle, and operating requirements of the door.

Installing a more powerful motor will not necessarily make the door stronger or more reliable. In fact, an oversized motor can place excessive stress on the axle assembly, barrel, suspension components, safety devices, and control equipment. Before upgrading motor size, it is important to establish the reason for the change and confirm that the entire door system is capable of handling the increased torque.

Increasing the Opening Speed

Some customers wish to upgrade to a faster motor to improve traffic flow or operational efficiency. While this can often be achieved, the door itself must be designed to operate at higher speeds.

Factors that need to be considered include:

• Curtain wind resistance and stability
• Guide rail design and wear characteristics
• Safety edge response times
• Brake performance
• Control panel compatibility
• Compliance with current machinery safety regulations
  

Operating a door faster than its original design specification can reduce component life and may compromise safety if the appropriate upgrades are not carried out at the same time.

Changing Between Single-Phase and Three-Phase Motors

Converting from a single-phase motor to a three-phase motor, or vice versa, is generally straightforward provided the correct power supply is available.

Many industrial motors are available in both single-phase and three-phase versions, allowing the motor and control equipment to be changed without major modifications to the door itself. Three-phase motors are often preferred for larger doors due to their smoother operation, improved efficiency, and higher duty cycle capabilities.

Changing from Inboard to Outboard Motors

Although it is technically possible to convert between inboard and outboard motor arrangements, this is rarely a simple motor swap.

The motor mounting system, axle assembly, support brackets, bearings, and drive arrangements are often completely different between the two designs. For this reason, if you wish to change from an inboard motor to an outboard motor (or vice versa), we would generally recommend replacing the complete axle assembly rather than attempting to adapt the existing components.

This ensures correct alignment, reliable operation, and long-term durability while avoiding compatibility issues during installation.

Our Recommendation

For most industrial roller shutters, the safest and most cost-effective solution is to replace the motor on a like-for-like basis using the same manufacturer and model wherever possible. Industrial motors are designed as part of a complete door system, and changing specifications without proper assessment can lead to performance, reliability, and safety concerns. If you are considering an upgrade, it is always worth discussing your requirements with a specialist before ordering replacement components.

When replacing an industrial motor, you must match:

• Motor type (single or three phase)
• Torque and lifting capacity
• Mounting configuration (inboard or outboard)
• Shaft and barrel compatibility

Using the wrong motor can lead to:

• Installation issues
• Poor performance
• Damage to the shutter system

Where possible, always replace like for like.

If the original motor is no longer available:

Option 1: Replace with a Compatible Motor
May require adapters or modifications

Option 2: Replace Full Axle Assembly (Recommended)

• Includes barrel, motor, and fittings
• Ensures full compatibility
• Faster and more reliable solution
  
  
  

Motor size is based on lifting capacity.

Key factors:

• Width and height of the shutter
• Curtain weight
• Frequency of use
• Type of application

Incorrect sizing can cause:

• Motor strain or failure
• Poor operation
• Increased wear
• Controls and Safety Features

Industrial motors can be used with:

• Push button stations
• Key switches
• Remote controls
• Automated systems

Safety Options:

• Safety edge (stops on contact)
• Light curtain systems
• Emergency stop

These are especially important on large industrial doors.

To help us identify the correct replacement, we will need:

• Photos of the motor and installation
• Motor type (single or three phase)
• Mounting type (inboard or outboard)
• Overall Shutter size (width and height)
• Usage level (daily cycles)
• Any motor labels or serial numbers
  
  
  
  
  
  
  

Replacing an industrial motor requires care due to the size and weight of the shutter system. For large doors, professional installation is recommended.

Step 1: Isolate the Power Supply

• Disconnect all electrical supply
• Ensure the shutter cannot be operated
• Confirm safe working condition

Step 2: Lower and Secure the Shutter

• Fully close the shutter
• Support the curtain if required
• Prevent movement during the repai

Step 3: Open the Shutter Box

• Remove the cover to access the motor and barrel
• Identify motor type and mounting setup

Step 4: Disconnect the Motor

• Disconnect electrical wiring
• Label connections if needed
• Isolate control systems

Step 5: Remove the Existing Motor

Inboard Motor:

• Remove chain drive
• Disconnect motor from barrel

Outboard Motor:

• Unbolt motor from endplate
• Slide motor off the shaft

Support the motor during removal, as it may be heavy.

Step 6: Inspect Barrel and Components

• Check shaft condition
• Inspect bearings and brackets
• Replace worn components if require

Step 7: Fit the New Motor

Inboard Motor:

• Reconnect chain drive
• Align motor within the endplate

Outboard Motor:

• Slide motor onto shaft
• Secure to endplate

Ensure:

• Correct alignment
• Secure fixing
• Proper engagement with the barrel

Step 8: Reconnect Wiring and Controls

• Reconnect electrical supply
• Ensure correct wiring configuration
• Check compatibility with controls

Step 9: Set Limits and Test Operation

• Set open and closed positions
• Run the shutter through full cycles
• Check for smooth, even operation

Ensure:

• No excessive noise
• Correct stopping points
• Safe operation

Step 10: Final Checks

• Tighten all fixings
• Confirm motor is secure
• Check safety features are working
• Refit shutter box cover
  
  
  
  
  
  

Compatibility and Fit

Industrial motors must match:

• Shaft size and type
• Endplate configuration
• Drive system (chain or direct drive)

Incorrect fit can lead to operational issues or failure.

Electrical Requirements

• Single phase (240V) or three phase (415V)
• Must be wired correctly
• Installed in line with electrical regulations
  When to Replace the Full System

Consider a full replacement if:

• Motor is obsolete
• Barrel or shaft is worn
• System is unreliable
• Upgrading from inboard to outboard

Maintenance Tips

• Regularly check motor operation
• Inspect chains (inboard systems)
• Test safety systems
• Schedule routine servicing