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How to Identify Whether Your Industrial Drive Is Repairable or Fully Dead ?
Introduction
When an industrial drive fails, it is often assumed by many plant teams that the only solution is to replace it. But in a real-world industrial setting, a high percentage of so-called “dead” drives can actually be repaired. This knowledge of the technical condition of the drive can help maintenance personnel make informed decisions and avoid unnecessary capital expenditures.
Conditions That Determine Whether a Drive Is Repairable or Fully Dead
Check the Power-Up Condition
The first and most crucial step is to see if the drive turns on.
Repairable Condition:
- Display turns on
- LEDs blink or stay steady
- Keypad reacts to input
This means that the control power part and logic board are operational, and it is highly likely that the industrial drive can be repaired.
Critical Condition:
- No display
- No LEDs
- No fan movement
This is usually an indication of internal damage, or blown internal fuses. These problems can still be fixed unless the main power board is badly burned.
- Interpret Fault Codes and Error Messages
The fault codes provide a quick status readout of the drive’s conidition.
Repairable Faults:
- Overcurrent (OC)
- Overvoltage (OV)
- Undervoltage (UV)
- Overtemperature (OH)
- Ground fault (GF)
These faults generally indicate:
- IGBT degradation
- DC bus capacitor aging
- Cooling system failure
- Poor input power quality
These are component-level failures, which are normally repairable.
Non-Repairable Indicators:
- Random unexplained errors
- Drive resets automatically
- No fault codes at all
This may suggest firmware corruption, microcontroller failure, or control board damage.
Physical and Visual Inspection
A professional examination may help to determine the actual state of the drive.
Repairable Signs:
- Poor cooling fans
- Swollen electrolytic capacitors
- Burnt gate drivers
- Single IGBT failure
These parts can be replaced individually.
Fully Dead Signs:
- Entire PCB charred
- Carbonized tracks
- Heavy corrosion
- Melted connectors
If the PCB layout is damaged, the industrial drive is usually no longer repairable.
- Understand the Root Cause of Failure
The way the drive failed is often more important than the symptoms.
Gradual Failures (Mostly Repairable):
- Chronic overheating
- Dust accumulation
- Continuous overload
- Lack of ventilation
These are progressive and easy to diagnose.
Sudden Failures (Often Dead):
- Lightning strikes
- Voltage spikes
- Phase-to-phase short circuits
- Water entry
These result in immediate damage to various parts.
- Communication and Control Issues
In modern automation systems, drives communicate with PLCs and SCADA via industrial protocols.
Repairable:
- Occasional communication loss
- Parameter write errors
- Network timeout faults
Usually caused of EMI, loose connection cards, or communication card issues.
Dead:
- No network detection
- Corrupted firmware
- Control board not booting
These indicate deep logic failure.
Economic Feasibility Check
Sometimes a drive is technically repairable but not economically practical.
If:
- Repair cost > 60–70% of new drive price
- Spare parts are obsolete
- Support from the manufacturer has caused Final Takeaway
Then replacement becomes the better long-term decision.
Final Conclusion
Most industrial drives do not die without giving signs of their impending death. Most drives begin with small electrical or thermal problems that develop over time. With proper diagnosis, most drives can be restored to their full functionality, extending their lifespan and reducing their operational costs. In industrial maintenance, diagnosis is almost always cheaper than replacement.
