Maximizing Your Uptime: Maintenance Tips and Tricks for Your PowerFlex 7 Series Drives

by Bryan Hellman March 19, 2025

In any industry, even a brief period of downtime can result in substantial financial losses. Proper maintenance is not just a routine task—it is a strategic approach to preserving the performance, reliability, and lifespan of your PowerFlex 7 drives. If done correctly, maintenance helps sustain these drives' performance and longevity. This comprehensive guide will cover the best maintenance practices to help you increase your system’s reliability and prevent costly failures.

Setting the Maintenance Cadence

A well-structured maintenance plan includes pre-scheduled periodic inspections. The first inspection should be conducted within 3-4 months after the drive is installed to identify any early-stage operational issues. Following this initial check, an annual maintenance schedule should be established.

Factors Affecting Maintenance Frequency:

Operational Conditions: Drives in high-duty cycle environments may require more frequent inspections.
Environmental Conditions: Dusty, humid, or high-temperature environments can accelerate wear and contamination.
Application Type: Some applications with frequent start-stop operations may demand closer monitoring.

A benchmark approach allows potential issues to be detected and resolved before they escalate, ensuring optimal drive performance.

Eliminating Contamination

Contamination from dust and debris negatively affects drive performance and can pose safety hazards. Accumulated particles can cause overheating, electrical arcing, and even fires.

Preventive Measures:

Inspect Enclosures: Ensure all enclosure openings are sealed properly to prevent dust ingress.
Proper Cleaning Techniques: Use vacuuming or wiping to remove contaminants. Avoid compressed air, as it can drive debris further into sensitive areas.
Replace Severely Contaminated Parts: If a component cannot be adequately cleaned, replacement is the safest option.

By keeping the drive free of contamination, you can significantly improve its reliability and safety.

Thermal Management

Effective thermal management is crucial for preventing overheating, which can degrade components and lead to failures.

Key Maintenance Steps:

Cooling Fan Inspection: Check for physical damage, bent blades, or blocked airflow. Momentarily apply power to verify fan operation.
Filter Maintenance: Reusable filters should be cleaned monthly and replaced every three months (or sooner in harsher conditions).
Heat Sink and Airflow Checks: Ensure proper ventilation and airflow to dissipate heat efficiently.

Cooling System Maintenance Schedule:

Monthly: Inspect and clean all cooling fans.
Every 5 Months: Replace cooling fans.
Annually: Inspect and clean major heat-sensitive components such as IGBTs and capacitors.

Proper thermal management extends component lifespan and improves overall system efficiency.

Preserving Bus Capacitors

Bus capacitors require careful monitoring, particularly during storage. Neglecting capacitor reforming can lead to premature failure when the drive is reactivated.

Reforming Guidelines:

Storage Under 2 Years: No reforming needed.
2 to 3 Years: Apply rated voltage under no load for 30 minutes.
Over 3 Years: Gradually ramp up DC bus voltage in steps of 50%, 75%, and 100% rated voltage.

DC Bus Voltage Ratings:

230V AC Input → 325V DC bus voltage
400/480V AC Input → 680V DC bus voltage
600V AC Input → 848V DC bus voltage
600/690V AC Input → 976V DC bus voltage

Before applying voltages, disconnect all internal stirring fans in frames 6 and 7 of the PowerFlex 753 and 755 models to prevent failures.

Ensuring Mechanical Integrity

Mechanical wear and tear can compromise drive performance. Routine inspections should focus on:

Tightening Fasteners: Loose fasteners can cause vibrations and misalignment.
Inspecting Relays and Contactors: Avoid lubricating Allen-Bradley contactors, as oil and grease can impair functionality.
Verifying Equipment Operation: Ensure moving parts function correctly without binding.

Regular checks prevent mechanical failures and improve drive longevity.

Maintaining Electrical Contacts

Reliable electrical connections are essential for consistent operation. Follow these maintenance guidelines:

Monitor Contact Wear: Slight discoloration is normal, but severe pitting requires replacement.
Avoid Sprays and Cleaners: Residues can cause sticking and disrupt continuity.
Replace Contacts in Sets: This ensures even pressure and alignment.

Good electrical contacts reduce resistance and minimize energy losses.

Terminal and Coil Maintenance

Loose terminals pose a fire hazard due to overheating and sparking. Periodic checks should include:

Tightening Connections: Ensure all terminals are secure.
Inspecting Coils: Look for insulation damage caused by overheating. Replace any damaged coils and address voltage issues.

Properly maintained terminals and coils prevent unexpected failures.

Solid-State Device Maintenance

Solid-state devices (SSDs), including printed circuit boards (PCBs), require minimal maintenance but should be checked periodically for:

Proper Seating in Connectors: Ensure secure placement and locked tabs.
Avoiding Solvents: Use dry cleaning methods to prevent chemical damage.
Regular Air Filter Cleaning: Ensures optimal airflow in blower-equipped drives.

Simple maintenance practices keep solid-state components in top condition.

Auxiliary Component Checks

Pilot Lamps: Replace burned-out bulbs or damaged lenses.
Locking and Interlocking Devices: Test for functionality and repair or replace as needed.

Ensuring these components function correctly enhances overall system reliability.

Leveraging Predictive Maintenance

Advanced drives, such as the PowerFlex 755T, feature built-in predictive maintenance technology. This system provides real-time insights into:

Fan Performance
IGBT Condition
Capacitor Health

Predictive maintenance helps schedule repairs before failures occur, reducing unplanned downtime.

The Importance of Record-Keeping

Accurate maintenance records allow for:

Tracking Recurring Issues: Helps identify patterns and root causes.
Efficient Troubleshooting: Reduces diagnostic time.
Inventory Planning: Ensures spare parts are stocked as needed.

Maintaining detailed logs ensures smooth operations and informed decision-making.

Final System Testing

After maintenance, always test the drive under controlled conditions to verify functionality and safety. This final check minimizes operational risks and ensures all components work correctly.

By following these best practices, you can maximize the uptime and reliability of your PowerFlex 7 drives. Preventive and predictive maintenance, combined with proper record-keeping, ensures your equipment runs efficiently for years to come.

We understand that maintenance tasks can be overlooked, and unexpected issues may arise. That’s why we offer repair services for PowerFlex 7 series drives. Additionally, we carry a wide selection of drives, backed by our 2-year warranty, ready to be shipped to your door. Contact us today to find the right solution for your automation needs!

For more insights, check out our blog on the differences between PowerFlex 7 series drives!