Variable Frequency Drives (VFDs) are vital for keeping industrial equipment running smoothly. When a VFD fails, the first thought is often whether it should be repaired or replaced. Both options carry costs, risks, and benefits, and the wrong choice can result in extended downtime and lost productivity.
The key is weighing the cost of each option against the urgency of getting equipment back online.
When Repair Makes Sense
VFD repair is often the faster and more cost-effective route, especially when the unit is relatively new or not heavily damaged. Common failures, such as power supply issues, failed capacitors, or board-level faults, can usually be repaired quickly by an experienced technician.
In these cases, the turnaround is shorter than waiting for a replacement unit to ship, which helps avoid production delays.
Repairs are also a strong option if the VFD model is discontinued but still widely used in your facility. Many older drives are no longer manufactured, which makes finding a direct replacement challenging. Repairing the unit keeps your equipment compatible with your existing setup without requiring costly reconfiguration.
Another point in favor of repair is cost savings. Rebuilding a VFD is typically a fraction of the price of purchasing new. For facilities that run multiple drives, these savings add up quickly, freeing budget for other critical needs. Plus, most reputable repair shops will stand behind their work with a warranty on the repairs they provide. ACS Industrial, for example, offers a two-year warranty on all repair work – you can have confidence knowing that your repaired equipment is covered in case anything goes wrong. This can also be a substantial money-saver.
When Replacement is the Better Choice
There are times, however, when repair is not the best long-term solution. If a drive has failed multiple times in recent years, it may be showing signs of age or wear that repair cannot fully resolve. In that case, a replacement prevents ongoing issues and gives you the confidence of new equipment under warranty.
Replacement is also the right move when the unit’s technology has become outdated. Newer VFDs often offer improved efficiency, better communication protocols, and enhanced safety features. If your facility is already planning equipment upgrades, it may make sense to replace the failing drive rather than put money into repairing old technology.
Another factor is lead time. In certain cases, replacement units may be available immediately, while repair could take longer due to parts availability.
If downtime is more costly than the price difference between repair and replacement, installing a new drive might be the smarter choice.
Balancing Cost and Downtime
The real decision comes down to balancing cost with the impact of downtime. Repair can be highly cost-efficient, but if the repair process takes longer than sourcing a replacement, the lost production may outweigh the savings. On the other hand, replacement provides a fresh start but carries a higher upfront expense.
Every situation is different, which is why many facilities work with a trusted repair partner who can diagnose the failure quickly and give an honest recommendation. Having an expert evaluation allows you to make the right call for both your budget and your production schedule.
At ACS Industrial, we specialize in VFD repair and understand how important these decisions are for keeping your operations moving. Whether you choose repair or replacement, our goal is to minimize downtime and keep your equipment running at peak performance.
Call ACS Industrial for Repairs and Service for Your VFDs!
Knowing how to keep variable frequency drives and other industrial electronics in operation can be tough, but you don’t have to do it alone. At ACS Industrial Services, we specialize in preventative maintenance and repair services for industrial electronic equipment.
With over 20 years of experience, ACS is a leading industrial repair service provider when things break. We repair many different components of machinery across various makes and models. We provide a rapid turnaround time. Most repairs are back in your hands within 7-15 business days, with our Rush Repair Service typically shipping in just 3-5 business days.
Contact us for a FREE evaluation and a no-obligation quote, or call (800) 605-6419.