A fan motor that is pulling excessive amps is either defective or doing more work than it was designed to do. You have 99.9% eliminated the first possibility by replacing the motor. If this is a long established system and the problem is just-now-new - then something has changed in the system to reduce resistance to air flow.
So, as I see it the options are these:
1. The best method is reduce the blower speed by adjusting the drive sheave to a smaller effective diameter until the amp draw matches the FLA / RLA listed on the motor's name plate.
2. The other way is to reduce the max allowable amps / motor speed by altering the freak drive's parameters.
3. Find out why and how the air system has changed in a way which has resulted in a lesser resistance to air flow.
What do you mean: "return fan motor" ? Is this a push/pull system in a large air handler or packaged unit?
Originally Posted by Onefast450r
The conventional view serves to protect us from the painful job of thinking.