VFD Capacitor Shelf Life,

Storage, and Reforming

EXECUTIVE SUMMARY
The question of Variable-Frequency Drive (VFD) shelf life is actually a question
of capacitor shelf life. There is a point at which that spare drive on the shelf will
require maintenance prior to applying rated line voltage. This white paper
summarizes the issues and the solutions.

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TABLE OF CONTENTS
INTRODUCTION .................................................................................................. 3
BACKGROUND/PROBLEM STATEMENT .......................................................... 3
SOLUTION ........................................................................................................... 4
CONCLUSION ...................................................................................................... 4
ADDITIONAL RESOURCES ................................................................................ 5

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INTRODUCTION
The electrolytic capacitors used in the DC bus power circuit of variable speed
drives have a minimum shelf life (as stated by the capacitor manufacturer) of 1
year from their last power up at working voltage. This is due to the degradation of
the oxide dielectric layer of the insulating materials in the capacitor. Each time
working voltage is applied to the capacitor, the charge on the capacitor “rebuilds”
this layer of oxide. Once an extended time period passes (generally over 1 year)
the degradation will introduce an ever-increasing risk of capacitor failure on
power up, if powered with full rated voltage. Capacitor failure will result, at a
minimum, in the loss of its capacitance value, and in the worst case, the VFD
needing repair or replacement.

BACKGROUND/PROBLEM STATEMENT
At the end user level, a VFD’s capacitor shelf life can become a concern with the
storage and management of spare parts stock for critical applications. Although
the component specifications use the word minimum, and this time is based on
the outer limits of the allowable storage temperatures, there is no statement to
give a shelf life time under better or ideal conditions. Electrolytic caps are
affected by temperature in that the higher the ambient temperature, the quicker
the electrical characteristics will deteriorate. It is possible that caps will need
attention within a year, or the reforming process won’t return them to full health.
VFDs have storage temperature and humidity specs that account for this. With
only the minimum shelf life as a guide, the derived storage shelf life of the VFD’s
capacitors is 1 year. This lack of more detailed guidance has led to many
questions as to what best practice is versus what is practical in the area of
storage and maintenance of spare variable frequency drives. This includes what
may need to be done when you are going to install a VFD that has been in parts
stock for an extended length of time.

On a more practical note, most VFD’s will not experience any problems upon
installation for several years after its shelf life has been exceeded. Each
organization will need to evaluate the amount of risk they are willing to accept
against the amount of time they spend minimizing the chance of failure.

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SOLUTIONS
There are two common methods of addressing the shelf life issue of VFD
electrolytic capacitors. The first is with pro-active preventative maintenance.
While the second is a reforming process once the shelf life has been exceeded.
Both have their pros and cons, but the best solution is regular maintenance.
There can be situations where reforming will not work.

The scheduled preventive maintenance approach would entail applying rated line
voltage to the line side of each unit for one hour once per year.

For drives that have not been powered up in over a year, it is recommended that
they go through a reforming process. For best results, this is a two-step
procedure.

Step 1 will be to slowly bring the voltage up to rated voltage. For step 1, voltage
should be increased slowly from zero to 25% of rated voltage, which must be no
load or current limited. The overall goal is to minimize the current flow that can
damage the layers that are exposed due to the oxide layer not being there. Then
let stand at 25% voltage for at least 15 min. Then increase the voltage to 50% for
another 15 min. Then repeat at 75% voltage. Finally increase the voltage to full
rated voltage, let stand for at least one hour, and proceed to step 2.

Step 2 will be leaving applied voltage on for 1 hour per year of shelf time.. Step 1
is most easily done with an AC variac (adjustable transformer). It’s acceptable to
use a DC supply if the DC voltage can be gradually increased to the nominal DC
bus voltage level. This procedure should be done by a qualified technician.
Please consult the manufacturer for the recommended connection points and/or
alternate reforming methods. Also, your manufacturer may offer a reforming
service through their service center(s).

CONCLUSION
If your spare parts stocking program includes variable frequency drives, a little
time spent in understanding VFD shelf life and how to help insure your spare
drive is ready when you need it will save you the cost of extended down time. In
most situations, the yearly preventative maintenance method is recommended.
This will allow your production to be up and running in the least amount of time.

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For more information, please contact Ashley Skidmore, ECMA Managing

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