Replacing Tube Motors

When replacing a tube motor, it is essential to match the original motor as closely as possible.

This includes:

• Brand of motor
• Motor size and torque rating
• Physical dimensions
• Drive and end adapters

Different manufacturers use different motor fittings, including:

• Motor heads
• Endplate brackets
• Drive wheels and adapters

If the wrong motor is selected, it may:

• Not fit into the existing barrel
• Not align with the endplates
• Cause operational issues

Always swap like for like wherever possible.

If your existing motor is discontinued or obsolete, there are still options.

In many cases, it may be easier and more reliable to:

Replace the full axle assembly (barrel, motor, and adapters)

This ensures:

• Full compatibility
• Correct alignment
• Reliable operation

Trying to adapt a different motor to an old system can often lead to:

• Additional parts required
• Increased installation time
• Potential long-term issues
  

Tube motors are sized based on their lifting capacity, known as torque.

Choosing the correct motor size is critical.

Factors that affect motor size:

• Weight of the shutter curtain
• Width and height of the opening
• Type of shutter (steel or aluminium)

Frequency of use

If the motor is too small:

• It may struggle to lift the shutter
• It can overheat or fail prematurely

If the motor is too large:

• It may cause excessive force
• Can lead to wear on components

Matching the original motor specification is the safest approach.

Standard Tube Motors

• Installed within the roller shutter barrel
• Operate on 240V single phase power
• Suitable for most domestic and commercial shutters

Heavy Duty Tube Motors

• Designed for larger or heavier shutters
• Provide higher torque output
• Suitable for more frequent use

Key Features to Consider:

• Built-in limit switches
• Thermal protection
• Compatibility with control systems
  

Replacing a tube motor should be carried out carefully, especially on larger shutters.

General Process:

• Isolate the power supply
• Open the shutter box
• Remove the shutter curtain from the barrel
• Disconnect and remove the existing motor
• Install the new motor with correct adapters
• Reconnect wiring and controls
• Set limits (open and close positions)
• Test operation

If you are unsure, we recommend using a qualified installer.

To ensure we provide the correct replacement motor, we will need:

• Motor brand and model (if known)
• Photos of the motor and endplate
• Axle Diameter and Shape
• Overall Shutter size (width and height)
• Type of shutter (steel or aluminium)
• Any markings or labels on the motor
• Description of the issue

This helps us match the correct motor and avoid compatibility issues.

Compatibility and Fit

Tube motors must match:

• Barrel size (e.g. 60mm, 70mm, 102mm)
• Drive and crown adaptersEndplate fixing
• arrangement

Incorrect fit can prevent installation or cause operational problems.

Electrical Requirements

• Most tube motors operate on 240V single phase
• Must be wired correctly to control systems
• Isolation is required before installation

Electrical work should be carried out safely and in line with regulations.

Limits and Setup

Tube motors use built-in limit switches to control travel.

These must be set correctly to:

• Prevent over-travel
• Avoid damage to the shutter
• Ensure smooth operation
  
  
  
  
  
  

In some cases, replacing just the motor is not the best option.

Consider replacing the full axle assembly if:

• The motor is obsolete
• The barrel or adapters are worn
• Compatibility issues arise
• The system has been modified over time

A full replacement can save time and improve reliability.

Step-by-Step Guide to Replacing a Tube Motor

Replacing a tube motor requires care, as the motor sits within the roller shutter barrel and supports the full weight of the curtain. It is important to ensure the replacement motor matches the original specification before starting.

If you are unsure, always seek professional assistance, especially on larger shutters.

Step 1: Isolate the Power Supply

Before starting any work:

Disconnect the power supply completely
Ensure the shutter cannot be operated
Confirm the system is safe to work on

Never work on a live motor.

Step 2: Lower the Shutter Fully

Lower the shutter into the fully closed position.

This helps:

• Take the weight off the motor
• Stabilise the curtain
• Make removal safer

If the motor has failed in the open position, the curtain may need to be supported manually before proceeding.

Step 3: Open the Shutter Box

Remove the shutter box cover to access the barrel and motor.

Check:

• How the motor is fitted
• Position of wiring
• Type of adapters and brackets

Take note or photos before removing anything, as this will help during reinstallation.

Step 4: Disconnect the Curtain from the Barrel

Detach the shutter curtain from the barrel.

This is usually done by:

• Removing locking straps or clips
• Releasing fixings between the curtain and barrel

Once released, carefully support the curtain to prevent it dropping or shifting.

Step 5: Remove the Barrel Assembly

The motor sits inside the barrel, so the barrel will need to be removed.

Steps include:

• Loosening the endplate fixings
• Sliding the barrel out of position
• Supporting the weight during removal

Take care, as the barrel and motor assembly can be heavy.

Step 6: Remove the Existing Motor

Once the barrel is removed:

• Slide the motor out of the barrel
• Remove the drive and crown adapters
• Disconnect any remaining wiring

Keep all adapters and fittings if they are being reused.

Step 7: Fit the New Motor

Install the new motor into the barrel.

Make sure:

• The motor matches the original size and specification
• Correct adapters (drive and crown) are fitted
• The motor sits securely within the barrel

If the motor is a different brand, new adapters may be required.

Step 8: Reinstall the Barrel

Refit the barrel back into position.

Check:

• Alignment with the endplates
• Secure fixing on both sides
• Smooth rotation

Ensure the motor head is correctly seated in the endplate bracket.

Step 9: Reconnect the Curtain

Reattach the shutter curtain to the barrel.

Make sure:

• Curtain is centred
• Fixings are secure
• Curtain feeds evenly into the guides

Incorrect alignment can cause tracking issues.

Step 10: Reconnect Power and Set Limits

Reconnect the electrical supply and set the motor limits.

This includes:

• Setting the top (open) position
• Setting the bottom (closed) position

Correct limit setting is essential to prevent:

• Over-travel
• Damage to the shutter

Step 11: Test Operation

Run the shutter through several full cycles.

Check for:

• Smooth operation
• Correct stopping positions
• No unusual noise
• Even movement within the guides

Step 12: Final Checks

Before completing the job:

• Ensure all fixings are secure
• Confirm wiring is safe and protected
• Refit the shutter box cover
• Check controls and safety features

A correctly installed motor should provide smooth, reliable operation.