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Byrnes Thickness Sander Advice

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While using my Byrnes sanding machine the motorit became very hot,next thing the plastic can mellted so i switched the machine off. At the time i had been using the machine


for twenty minuetes and had been sanding at 0.05 metric or two thou a pass on pieces of Beech.I had to take the machine to a motor repair specialist who fitted a new plastic can


Can anybody give me any advice on what i did wrong i would welcome any tips.


                                 Regards.   janet bode

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Hi Janet. I've used my Byrne's sander for an hour doing boxwood and not had any issues. The only thing I can think would cause it to heat up would be too heavy a load by pushing the wood through at too fast a pace. 


Might want to email Jim Byrne's and get his opinion. 


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Hi Janet, as the first option I would contact Jim as he is very helpful with these matters.


I have used the machine for prolonged periods with no issue (thicknesser and disk sander).  You did not specify which, but recently I had an issue with the switch/capacitor of my disk sander and Jim helpfully sent me a replacement - it burnt out on me but I noticed it and stopped the machine immediately.  You may have experienced a similar issue?  I hope the tech checked the motor for you also as some of these motors do not like being overheated.





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I would suggest you describe your episode as accurately as possible to Jim Byrnes as it could have been any number of things including the motor itself (faulty field winding, capacitor start circuit), your power source (brown out conditions), loading i.e. rate of feed, how much you tried to remove in a pass.


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I’ve had some issues with my 230V disc sander overheating. The motor will simply switch itself off when it gets too hot, Once it cools down again it can be re-started and appears to run fine. Only seems to happen if its been running for a long time, rather than in response to loading from the workpiece. Just thought I’d mention it in case it is a common problem with the 230V motors.

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Janet and others


I got this from the motor manufacturer this morning


The factory reviewed this issue and provided the following feedback:


Here is the preliminary analysis and investigation for this issue:


The motor insulation class is B that has a temperature rating of 130C (266F). This motor also has a thermal protector attached on the winding which will protect for over-heating. When the temperature is over 110C (230F) on the winding, the thermal protector will trip for protection. After cooling under 100C (212), the motor can work again. Usually the housing temperature is 20 degrees less than the winding. When the housing temperature is over 65C (149F), it will feel hot to your hand. Therefore, it is not surprising that you can not touch the motor housing. The odor that the customer smelt is from the volatilization of the varnishing with the stator, NOT the paint. In another words, as long as the motor internal temperature is not over 110C (230F), the motor will work. Once it is over 110C, the thermal protector will provide protection for the motor so it would not be damaged, so the motor design is safe.



after 35 minutes of constant run time the 230v motor would be about 75C or 167F,  too hot to handle but will not damage the motor


They also included 35 pages of all the testing they have done over the years.  


So,  the motors will run hot,  it doesn't damage the motor


The "plastic can" that melted on your motor was the capacitor and that is very unusual.  We have only replaced 2 or 3 over the years.  Please make sure the capacitor that was replaced is marked 12uf and no higher or it may burn the motor out








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  • 4 weeks later...



Is it a capacitor start or does it also use it for capacitor run? If only for start is it possible that it did not switch out and hence cause the overheat of both capacitor and motor. It doesn't appear that Janet was particularly overloading the motor. 


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  • 6 years later...
Posted (edited)

I have the same issue with heating, I have the reversable DC motor of the new sander, my motor produced smoke and died, it does not seem to have protection? anyone can suggest a replacement motor? I couldn't find it anywhere, the specs Jim had referred to are not available to open or download. this is what is written on it:
DC Motor (90V 40W) - (TYPE ZYT -63-12)

Edited by Rafael9
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