Seasonal Shutdowns: How to Protect Drives & Motors (and Avoid Costly Restarts)

As we approach the winter slowdown in late September 2025, many factories are preparing for seasonal shutdowns—whether for holidays, maintenance, or reduced demand. These pauses are useful, but idle variable frequency drives (VFDs) and motors face risks like moisture, corrosion, and lubricant breakdown. A single failure at restart can cost thousands in repairs and lost production.

Industrial Automation Co. supports plants through shutdowns and restarts year-round. Below are proven steps to protect equipment and reduce downtime—plus a few in-stock parts you can stage as spares for faster recovery.

Why Idle Equipment Is at Risk

Moisture & corrosion: Condensation in cool spaces leads to oxidation on terminals, windings, and bearings. Bearing & lubricant issues: Grease can settle or harden; shafts sitting in one position can develop flat spots, raising vibration on startup. Electrical aging: VFD DC bus capacitors slowly lose charge and can struggle at first energization. Dust & debris: Clogged vents and heatsinks reduce cooling, pushing drives into over-temp faults.

2–4 Weeks Before Shutdown: Prep Work That Pays Off

Inspect thoroughly. For motors, listen for unusual noise, check temperature trends, and test insulation resistance. For VFDs, look for condensation or corrosion, tighten terminations, and confirm firmware is current. Log what you find so you can compare after restart.

Clean carefully. Blow out dust from motor fins and VFD heatsinks with low-pressure air (< 30 psi) or a soft brush. Replace/clean filters in enclosures to keep airflow up.

Lubricate correctly. Use the manufacturer-specified grease or oil and avoid over-lubrication, which can migrate into windings and seals.

Make it electrically safe. De-energize, wait for VFD DC bus to discharge per the manual, and cap or protect open terminals. Light anti-corrosion spray on terminal hardware helps in humid environments.

During the Idle Period: Keep Equipment Healthy

Control the environment. Indoors, target > 40 °F (4 °C) and < 50% RH. Use dehumidifiers or desiccants. For semi-exposed gear, gentle enclosure heat and breathable covers prevent condensation (avoid plastic tarps that trap moisture).

Turn shafts periodically. Every 2–3 weeks, rotate motor shafts 10–15 turns to redistribute grease and prevent brinelling.

Re-energize drives periodically (if allowed). For long idle windows, a brief, no-load power-up helps “wake” capacitors. Follow the OEM’s guidance—some families specify gradual voltage application.

Optional monitoring. Low-cost sensors for temperature, humidity, or vibration can flag problems before restart day.

Recommissioning: A Smooth, Low-Stress Restart

Pre-start checks: Re-inspect for dust, corrosion, loose connections, and leaks. Verify alignments and belt tensions; re-lube if required.

Capacitor reforming (when idle > 12 months): Apply voltage in steps (e.g., 25% → 50% → 100%) per the drive manual to rebuild dielectric layers.

Test run: Start at low load while watching current, vibration, and temperature. Increase load over 24–48 hours rather than hammering full production immediately.

Smart Spares to Stage Now (Faster Recovery Later)

Even perfect maintenance can’t stop every failure. Staging a few spares turns multi-day waits into same-day fixes.

• Allen-Bradley PowerFlex 525 VFD – 480 V, 1 HP class: 25B-D2P3N104. A widely used general-purpose drive with quick setup and robust diagnostics—ideal as a “get-running” spare for small fans, pumps, and conveyors.
• Control panel electronics for fast swaps: If you also keep PLC-side spares, consider a swappable analog input like 1756-IF16 to avoid full controller replacement when a single card faults.

Need a different HP, voltage, or enclosure? Tell us the motor nameplate and the failed model—we’ll match a drive that fits your panel and wiring with minimal changes.

Get Help Matching a Drive or Motor

Bottom Line

Seasonal shutdowns don’t have to invite failures. With simple prep, periodic care during the idle window, and a few strategic spares, you can protect VFDs and motors and restart smoothly in 2026.

Industrial Automation Co. offers same-day shipping, a 2-year warranty, and free technical support. If a drive fails during restart, we’ll help you source a compatible replacement fast.

Talk to an Engineer Today