Obsolete variable frequency drives create a difficult reliability problem: the equipment may still operate, but replacement parts, technical support and direct replacement models become harder to obtain. IPS helps customers plan for VFD obsolescence before it becomes an emergency and provides options ranging from repair and sourcing obsolete equipment to upgrading to modern VFD technology.
Start Planning at the First Obsolescence Notice
VFD manufacturers typically communicate the stages of a product’s life cycle and obsolescence. A manufacturer may notify customers that a legacy drive family is entering an initial stage of obsolescence while continuing to provide parts and support for a defined period of time.
The first manufacturer obsolescence notice should be viewed as the beginning of the customer’s planning process—not the end of the drive’s useful life. This is the ideal time to identify the affected VFD population, determine which drives are critical to production, review available spare units and replacement parts, and develop a long-term repair or modernization strategy.
Waiting until manufacturer support has ended can turn a manageable equipment transition into an emergency. Planning early gives facilities time to budget, evaluate replacement technology, address controls and communications, and schedule upgrades around planned outages instead of production failures.
When Is a VFD Obsolete?
A drive may be considered obsolete or approaching obsolescence when the manufacturer begins reducing support, critical components become difficult to obtain, factory replacement units are discontinued, or the installed platform creates an increasing downtime risk.
30+ Years of Obsolete VFD Sourcing Experience
Not every obsolete VFD needs to be immediately replaced with a new platform. Over more than 30 years in the industrial electronics and VFD business, our Folcroft team has developed a strong network of trusted vendors that stock surplus and obsolete drives and components.
This network can help us locate difficult-to-find legacy VFD equipment from manufacturers including Allen Bradley, Toshiba, WEG, Gefran, Eaton, ABB, LS Electric and Yaskawa. Availability varies by model, but access to trusted surplus sources can provide customers with another option when an obsolete drive fails or when maintaining strategic spares is important to plant reliability.
Repair Can Buy Time
In many cases an obsolete drive can still be repaired. A successful repair can restore equipment to service while giving the facility time to develop and execute a controlled migration plan rather than making a major equipment change during an emergency shutdown. Our VFD repair vs. replacement guide explains how to compare the total cost and operational impact of each option.
Upgrade Obsolete VFDs to Modern Drive Technology
When continued repair or sourcing of obsolete equipment is no longer the best long-term solution, IPS can help replace legacy VFDs with modern drive equipment designed to perform as well as or better than the existing system. A properly engineered modernization can improve reliability while maintaining the motor and application performance the facility requires.
Our team evaluates the complete application rather than simply matching the horsepower on the old drive. This includes motor voltage and current, overload requirements, control method, speed reference, communications, enclosure, bypass requirements, physical installation and application duty. Where necessary, we can also help address differences between legacy controls and modern VFD technology.
Information Needed for Replacement
- Existing VFD manufacturer and complete model number
- Motor voltage, horsepower and full-load current
- Input power and phase
- Application and load type
- Enclosure and environmental requirements
- Control wiring and speed reference
- Network or communication requirements
- Bypass or safety requirements
More Than Matching Horsepower
A successful retrofit requires more than selecting a drive with the same HP rating. Output current, overload duty, control method, physical installation, communications and application requirements should all be considered. IPS can also provide VFD startup and commissioning support for replacement installations.
Develop an Obsolescence Plan Before the Failure
IPS can help customers review installed legacy VFDs and determine which equipment should continue to be repaired, which drives warrant strategic spares, and which systems should be prioritized for modernization. Developing that plan while equipment is still operating provides far more options than making those decisions after a critical drive fails. A VFD preventive maintenance program can also help identify developing issues in critical drive populations.
Need Help With an Obsolete VFD?
Use the IPS VFD sizing tool or contact IPS with the existing manufacturer, model number and motor information. We can help evaluate repair, obsolete/surplus sourcing or a modern replacement strategy.