ACS550 Variable Frequency Drive
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Product Information
Specifications
- Manufacturer: Precision Electric, Inc.
- Contact: 574-256-1000
- Website: www.precision-elec.com
Product Usage Instructions
Why VFD Models Become Obsolete
Various VFD models become obsolete due to technological
advancements and component shortages in the industry.
Challenges of Obsolescence and Long Lead Times
Obsolete VFD models may pose challenges in terms of availability
and lead times for replacements.
Examples of Discontinued VFD Models and Replacements
It is essential to identify discontinued VFD models and their
recommended replacements to ensure smooth operations.
Backward Compatibility and Retrofit Issues
Consider electrical, mechanical, and software compatibility when
replacing obsolete VFD units to avoid issues.
Mitigating Downtime: Strategies for Replacement and Spare
Management
Proactive steps can be taken to minimize downtime and facilitate
the transition to newer VFD models.
Real-World Impact: Downtime and Substitution Challenges
Understanding the impact of downtime and substitution challenges
can help in making informed decisions regarding VFD
replacements.
Practical Advice for Switching Models or Brands
Engineers and procurement professionals should follow a
checklist of advice when switching to newer VFD models or
brands.
FAQ
Q: How to verify compatibility when replacing an obsolete
VFD?
A: Engineers should review manuals, check electrical,
mechanical, and software compatibility, and verify cable lengths
and conduit entries.
Q: What are some strategies to mitigate downtime during VFD
replacement?
A: Facilities can take proactive steps, such as spare
management, to reduce the risk of downtime during VFD
replacements.
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Precision Electric, Inc.
Obsolete VFD Models and Replacement
Availability: Challenges and Solutions
Variable Frequency Drives (VFDs) are critical to industrial operations across North America, but even these workhorses have finite product lifecycles. Manufacturers periodically retire older VFD models (“obsolete” drives) and introduce new series, leaving engineers and maintenance teams grappling with long lead times and compatibility questions. This article provides a broad overview of the obsolescence challenges across multiple major VFD brands (ABB, Hitachi, Eaton, Lenze, Yaskawa, etc.), with real examples of discontinued models and recommended replacements. We’ll explore the risks of running obsolete drives, the impact of recent supply chain disruptions, and practical advice for managing replacements or cross-brand substitutions.
Why VFD Models Become Obsolete
VFD manufacturers routinely update their product lines to introduce improved features, comply with new regulations, or address component availability. For example, in 2017 Lenze announced it would gradually phase out its 8200, 9300, and SMD series drives to meet the EU RoHS directive limiting hazardous substances 1 . Newer Lenze 8400 and i500 series drives were introduced as successors offering modern compliance and capabilities. Similarly, Hitachi recently began phasing out the popular WJ200 drive series and introduced the WJ-C1 series as a drop-in replacement in its place 2 . Obsolescence is a normal part of the product lifecycle but it can pose challenges when older drives in the field eventually fail or require expansion.
Across manufacturers, many legacy VFD families from the 2000s and 2010s are now considered “classic” or discontinued. ABB, for instance, has migrated its general-purpose and high-performance drives to newer platforms: the ACS580 series replaced the aging ACS550 series, and the ACS880 family superseded the wellknown ACS800 line 3 4 . ABB formally announced that the ACS550 (along with related ACH550 and ACQ550 models for HVAC and pumping) would enter the retirement phase by 2021 in North America 5 . In practice, this means the older ACS550 drives are no longer in regular production and will only be available as limited spares. (One ABB partner noted that ACS800 drives, once “much-loved” by engineers, became available only as special-production spares with 10+ week lead times and higher prices after their successor launched 6 .)
Other brands have followed a similar trajectory. Yaskawa announced in early 2023 that its longstanding A1000, V1000, and J1000 drive series would be fully discontinued by March 2024, with the new GA500 (micro drive) and GA700 (industrial drive) series taking their place 7 8 . Yaskawa warned customers that during the phase-out period, support for the old models could become limited due to component shortages
9 . And Eaton, which had long marketed the Cutler-Hammer 9000X drive family (SVX9000, HVX9000, etc.), has transitioned to its newer PowerXL series. The legacy Eaton SVX9000 general-purpose drives were actually built on a Danfoss platform so when Eaton stopped offering them, users could still obtain an equivalent Danfoss VFD (the NXS series) as a one-to-one replacement 10 . Eaton’s newer drives like the DG1 (PowerXL series) now serve as the modern substitutes for those older 9000-series units.
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Precision Electric, Inc. Challenges of Obsolescence and Long Lead Times
When a drive model goes obsolete, the most immediate challenge is availability. Spare units and replacement parts become harder to find and more expensive. In the case of Lenze’s retired 8200/9300 series, supply in the open market “rapidly decreased” and prices climbed accordingly 11 . Many manufacturers offer a last-time-buy opportunity or limited production of spares, but as noted, these often come with extended lead times. For example, after ABB’s ACS800 entered its obsolete phase, fulfilling an order could take around 10 weeks and carry a significant price premium since it was outside normal production runs 6 . Users who don’t plan ahead may face lengthy downtime if an old drive fails unexpectedly.
Recent global supply chain disruptions have greatly amplified this risk. The semiconductor chip shortages of 20212023 hit industrial electronics hard, and VFDs were no exception. Lead times that used to be a few weeks stretched into several months or more at the peak of the shortage. In early 2022, some companies reported standard drive deliveries slipping from 4 weeks to 40 weeks nearly a year 12 . In one anecdote, an engineer seeking a 0.5 HP VFD was initially told stock was available, only to be informed the unit actually had a 40-week lead time due to unforeseen supply issues 12 . Manufacturers like ABB and Eaton, among others, struggled to meet demand during this period, forcing many customers to scramble for any available alternative. Engineers on technical forums discussed switching to whatever brand could ship drives fastest for instance, replacing an unavailable ABB or Allen-Bradley unit with a Schneider Altivar drive that distributors happened to have on the shelf 13 14 .
The good news is that by mid-2023 the VFD supply situation began improving as chip production caught up. Industry suppliers observed lead times coming back down into the 48 week range, with many common models even in stock again 15 . However, the tumultuous years underscored an important lesson: relying on an obsolete drive model (or a single supplier) without a backup plan can leave an operation vulnerable. A prolonged line-down situation waiting for a hard-to-find drive can be extremely costly in terms of lost production. In high-volume manufacturing, every hour of downtime counts, so long lead times for replacements are more than just an inconvenience they’re a serious business risk.
Examples of Discontinued VFD Models and Replacements
Obsolescence is affecting VFD users across a wide range of manufacturers. Below are a few notable examples of older drive series and their recommended replacements:
· Lenze: The 8200 Vector series (popular in the 2000s) has been fully discontinued and succeeded by the Lenze 8400 range of inverter drives. A Lenze support note confirms that “the 8200vector series is replaced by the new 8400 series” 16 , which comes in various models (StateLine, HighLine, etc.) to cover different applications. Likewise, the Lenze 9300 servo drives and SMD simple drives were retired due to RoHS regulations, with newer offerings like the i500 series taking their place 1 . Users with Lenze 8200 drives have found that the 8400 series provides equivalent functionality, though some parameter reprogramming is needed when upgrading. (One industry forum member noted the 8200 drives had been “obsolete for a while” and that even Lenze’s own support had lapsed, which partly drove their decision to switch to ABB drives instead 17 18 .)
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· Hitachi: The Hitachi WJ200 microdrive series (widely used in the past decade for 0.510 hp range motors) is being phased out as of 2024. Hitachi’s new WJ-C1 series is designed as the direct successor. Fortunately for users, the WJ-C1 was engineered for easy backward compatibility: it has the same mounting footprint and maintains the same control terminals and communication protocols as the WJ200, making it a straightforward drop-in replacement in most cases 19 20 . Hitachi also added some usability upgrades (for example, replacing the old up/down keypad with a modern jog dial interface) without fundamentally changing the drive’s I/O or basic functions 21 . Moreover, the WJ-C1 firmware allows transfer of parameter settings from a WJ200 drive via an optional keypad module or PC software, greatly simplifying migration of drive programs 22 23 . (The new WJ-C1 is stated to be “upwardly compatible” with WJ200 configurations, aside from a few new parameters that may need manual adjustment 24 .) In short, Hitachi has provided a clear upgrade path for WJ200 owners to move to WJ-C1 with minimal hassle.
· ABB: ABB has systematically rolled out new generations to replace its legacy drives. The legacy ACS550 general-purpose drives (and related ACH550 for HVAC and ACQ550 for pumping) were replaced by the ACS580/ACH580/ACQ580 family, which offer updated control features and connectivity. ABB’s official life-cycle announcement notes that the ACS580 line “has replaced ACS550” on the market 3 , and that the older 550-series was slated to move into retired status (“Classic phase”) by mid-2021 in the U.S. 5 . Similarly, the high-performance ACS800 series (introduced in the early 2000s) has been succeeded by the current ACS880 series. ABB introduced the ACS880 around 2014 as a “worthy successor” with improved control (e.g. built-in SIL3 safety, updated DTC motor control) and expanded capabilities to meet modern demands 25 26 . By 2017, ABB and its partners were actively encouraging users to transition from ACS800 to ACS880 or to the ACS580 in appropriate applications 4 . It’s worth noting that physical and electrical differences exist for example, the ACS580 drives are not exactly the same dimensions as the old ACS550, so retrofitting may require re-drilling mounting holes or adjusting cabinet layouts 27 . ABB provides detailed replacement guides to help users match new models to old and transfer settings, covering everything from dimension checks and wiring to ensuring any necessary options (like encoder feedback or communications modules) are accounted for 28 29 . These guides emphasize gathering the old drive’s parameter list and application details beforehand, since not every parameter or add-on of the ACS550 has an identical counterpart in the ACS580 (for instance, if an ACS550 used an encoder module or a NEMA 4X remote keypad, special considerations or higher-tier replacements may be needed, such as using an ACS880 in lieu of ACS580 in those cases 29 ).
· Yaskawa: Yaskawa’s well-known V1000 and A1000 drives (and the smaller J1000) were mainstays in many OEM machines and facilities. As of 2023, Yaskawa is retiring these lines and fully transitioning to the GA500 (for low-power applications) and GA700 (mid-power range) series as replacements 8 . The GA500/700 drives come with updated features like embedded Bluetooth apps, improved autotuning, and support for both induction and permanent magnet motors. Yaskawa’s official announcement gave customers a one-year last-buy window until March 2024, after which no new orders for V1000/A1000 would be accepted 7 30 . During the phase-out period, Yaskawa cautioned that it cannot guarantee full support or spare parts for those legacy drives, especially if component suppliers stop production earlier than Yaskawa’s own timeline 31 . Users are therefore encouraged to plan migrations sooner rather than later. Yaskawa offers transition guides to map V1000 settings to the new GA500, helping to minimize re-engineering effort 32 . In general the new GA drives have been designed to fit in the same general envelope and use similar programming methodology, but some re-wiring or parameter conversion is inevitable. For example, the GA500 has
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expanded I/O and different default parameter codes compared to a V1000, so technicians should not assume a plug-and-play swap without reviewing the manuals.
· Eaton: Eaton’s legacy “9000X” drive family (a series originally branded under Cutler-Hammer) included the SVX9000 (general-purpose), SPX9000 (high-performance), HVX9000 (HVAC), and various smaller drives like the MVX microdrive. Over the last decade, Eaton rebranded and updated its lineup to the PowerXL series. The modern equivalents are drives like the PowerXL DG1 (which covers the general-purpose segment up to 600 HP or more) and the PowerXL DC1/M-Max micro drives for lower horsepower. Officially, Eaton no longer sells the SVX9000/HVX9000, but because these models were originally based on Danfoss technology, users have an alternate support path: the Danfoss VLT NXS and NXP series drives are essentially the same hardware with a different nameplate. Distributors have noted that a Danfoss NXS can serve as a direct form-fit replacement for any Eaton SVX9000, with identical programming, wiring, and dimensions 33 . This is a fortunate case of crossmanufacturer compatibility that allowed some companies to keep running without a full system redesign. For completely new installations or major upgrades, however, migrating to Eaton’s current PowerXL drives is advisable. The PowerXL DG1 drive, for instance, has been positioned as the successor to the SVX for most industrial applications 34 35 . When undertaking such a change, one must account for differences in control terminals and configuration software (the DG1 uses Eaton’s modern interface, whereas the old SVX was programmed via a Danfoss tool or Eaton’s legacy software). In practice, organizations that had a mix of Eaton/Danfoss drives sometimes opt to standardize on one brand during upgrades whether sticking with Danfoss for continuity or switching to a different vendor entirely if lead times or support are better.
· Other Manufacturers: The trend of product-line refreshes is industry-wide. Rockwell Automation (Allen-Bradley), for example, has been migrating users from older PowerFlex 4/40 drives to the newer PowerFlex 525 series, and from PowerFlex 700/750 legacy models to enhanced versions of the PowerFlex 755 and newer architectures. Schneider Electric consolidated many of its Altivar drives (like the Altivar 61/71) into the newer Altivar Process (ATV600/900) series over the past decade. Siemens moved from MicroMaster drives to the current Sinamics line. In all cases, the newer models bring benefits (better efficiency, connectivity, and often smaller size), but the onus is on the end user to manage the transition smoothly.
Backward Compatibility and Retrofit Issues
Replacing an obsolete VFD is rarely as simple as unboxing a new unit and plugging it in. Engineers must carefully consider backward compatibility on multiple fronts: electrical, mechanical, and software. Here are some common issues and solutions:
· Physical Mounting and Wiring: Even when a manufacturer markets a new drive as a “drop-in replacement” for an old one, minor differences can creep in. The replacement might have a different footprint, mounting hole pattern, or overall size. For instance, ABB’s ACS580 drives are not identical in size to the older ACS550 units they replace, which may require panel modifications or re-routing cables if space is tight 27 . Always check dimensions and heat dissipation requirements of the new drive. Likewise, terminal layouts often change generation-to-generation the control wiring terminals might be in a different order or on a removable connector whereas previously they were fixed, etc. During a retrofit, technicians should label and verify every control wire and ensure the new drive’s terminal assignments match the functions (e.g. analog inputs, digital I/O for start/stop, relay
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outputs for fault signaling). It’s wise to leave some slack in wiring if possible; a new drive whose terminals are a few inches offset from the old one can otherwise turn into a tedious rewiring exercise if the existing wires are cut exactly to length. One replacement guide suggests verifying that all cable lengths and conduit entries will suit the new unit, and that any remote keypad or panel cutouts are compatible (or have a cover plan if not used) 36 37 .
· Parameter and Programming Differences: Every VFD model has its own set of parameter codes and firmware behaviors. Moving to a new model even from the same brand means you cannot simply swap the control boards and expect the drive to run. The configuration must be transferred. In the simplest cases, this is just a matter of re-entering motor data and application setpoints into the new drive’s programming. However, when an old drive had a complex setup (multiple presets, custom ramp times, communication settings, PID loops, etc.), the migration can be error-prone. Some manufacturers provide conversion tools or procedures to ease this burden. We saw that Hitachi’s WJ-C1 allows uploading the parameter file from a WJ200 via software or a handheld operator panel 22 , then automatically translates and imports the settings. This can save a lot of time and reduce mistakes, as long as the old drive’s configuration file was saved or the drive is still functional to read from. Yaskawa likewise publishes a “transition guide” mapping each V1000 parameter to the equivalent in GA500, since the numbering scheme differs. Even without an automated tool, a thorough comparison of parameter lists from old to new is essential this will highlight any settings that don’t directly carry over. It’s common to find that some parameters have expanded ranges or new default values in the newer model (for example, the max frequency setting might default to 590 Hz instead of 400 Hz on Hitachi WJ-C1, because the new drive can support higher-speed motors 38 ). After programming the new drive, functional testing is a must. Run the motor and verify that it accelerates, decelerates, and responds to commands as expected. Any special features (external braking units, multi-motor configurations, safety interlocks) should be tested, as the enabling method for these can vary between drive generations. If the original drive is completely inoperable (no way to read its program), one should retrieve as much information as possible from system documentation or PLC logic to rebuild the drive settings from scratch.
· Backward Compatibility of Accessories: One often overlooked aspect is the compatibility of peripheral devices. Many drives have optional accessories communication modules (Modbus, Profibus, Ethernet/IP cards), dynamic braking resistors or choppers, operator keypads, etc. When upgrading to a new drive model, these accessories from the old drive may not work with the new unit. For instance, ABB’s comparison guide notes that an encoder feedback option used on an ACS550 cannot be directly used on an ACS580 (which doesn’t support that option), so the solution might be to move up to an ACS880 or add an external encoder interface in the system 29 . Similarly, a remote keypad/display that was mounted on a panel door for an older drive might need a new adapter or entirely new keypad for the new drive. Plan for these during the retrofit check the new drive’s catalog for any accessory conversion kits. If a certain communication protocol was used (say a DeviceNet or PROFIBUS card on the old drive), make sure the new drive has an equivalent option or some gateway to interface with your control system. In some cases, users have found clever workarounds for example, when Eaton’s HVX drive (which had a specific serial communications module) was discontinued, a PLC integrator might temporarily use the same protocol via a different brand’s drive or add a protocol converter, until a proper replacement drive was integrated.
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· Software and Tuning: Using a new drive often means using new software for configuration/ monitoring. Technicians should be prepared to learn the updated software interface (many modern drives have PC tools with wizards and even mobile apps, which can differ substantially from the DOSor Windows XP-era tools that older drives used!). Tuning procedures for motor control might also differ. For instance, if a process relied on a drive’s internal PID controller, the tuning constants on a new drive may need adjustment to achieve the same response. In one case study of a retrofit on a coating line, 20-year-old DC drives each had their own self-contained PID loops for tension control, which were not performing well; the upgrade replaced those with AC drives and moved the tension control into a central PLC, yielding far better stability 39 40 . This illustrates that an upgrade can be an opportunity to simplify or improve the control architecture rather than trying to exactly duplicate the old behavior.
· Backwards Compatibility vs. “Future-Proofing”: There is sometimes a tension between making the new drive mimic the old one exactly and taking advantage of new features. While the immediate goal is usually to get the machine running again with minimal changes, it’s worth evaluating the enhancements the new drive offers. Features like advanced diagnostics, network connectivity, or safety functions (e.g. safe torque off) might provide long-term benefits. For example, if an older drive had no network capability and relied on hardwired signals, the new drive might allow an Ethernet connection to the PLC which could be leveraged for detailed monitoring or faster control in the future. Even if you don’t enable all the new features on Day 1, being aware of them can guide you to at least wire and configure the drive in a way that doesn’t paint you into a corner. One practical tip is to check if the new drive’s default control mode or I/O configuration differs from the old and adjust it to match the incumbent system as needed. Some drives have multiple control modes (e.g. local keypad, terminal, network) and may ship in a different mode than your old unit used; you wouldn’t want to spend hours chasing a “fault” only to realize the drive was expecting a serial start command instead of reading the terminal strip like the old one did.
Mitigating Downtime: Strategies for Replacement and Spare Management
When faced with obsolete drives, facilities can take proactive steps to mitigate the risk of downtime and ease the transition to newer models:
· Identify and Track Obsolete Components: First, conduct an audit of the drives installed in your plant or equipment. Which models are still current, and which have been declared end-of-life by the manufacturer? Many companies maintain an internal “obsolescence tracker” for critical components. Manufacturers often publish product lifecycle status on their websites or via notices. (For instance, ABB and Yaskawa publicly list when a drive is in Active, Classic, Limited, or Obsolete phase, as we saw above 41 7 .) By knowing ahead of time which drives are heading toward obsolescence, you can plan budget and maintenance activities accordingly. It might make sense to purchase a couple of spare units or critical spare parts (fans, circuit boards) for a soon-to-be-obsolete drive while they are still available at reasonable cost. This acts as an insurance policy if one fails unexpectedly.
· Leverage Manufacturer Cross-Reference Guides: Virtually all major drive makers provide replacement guides or cross-reference tools to help customers find the correct modern equivalent for an older model. These guides (often available as PDFs or online selection tools) are extremely
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useful they not only suggest the new model number that matches your old drive’s ratings, but also highlight differences and required option kits. For example, ABB’s official replacement guide for ACS550-to-ACS580 walks the user through selecting the proper ACS580 by matching power and voltage, and includes a checklist of items to consider (terminal wiring changes, ensuring cable lengths, verifying if an encoder or special I/O was used, etc.) 28 36 . Yaskawa’s transition documentation for V1000 to GA500 similarly ensures you order any needed terminal adapter so the wiring can be reconnected easily, since the GA500’s terminal block design differs from the V1000. By using these resources, you can avoid the pitfall of ordering what looks like a correct replacement, only to find out you needed an extra memory module or a different parameter unit for full compatibility. Manufacturers’ application engineers or authorized distributors can also be invaluable don’t hesitate to reach out to them with your legacy model number and ask for recommended replacements and migration advice. They may point you to firmware tools (for parameter conversion) or caution against common mistakes others have made in similar retrofits.
· Plan Retrofit Projects During Scheduled Downtime: One of the biggest concerns with replacing drives is the downtime required to do the changeover and re-commission the system. In continuous process industries, taking a line down for even a day can be hugely expensive. Thus, if possible, coordinate drive upgrade work with planned outages or slow production periods. Some companies choose to do a pilot retrofit on one machine or line first, to work out any kinks, and then roll out the changes to other lines later. A real-world example comes from a printing company that had multiple identical drive systems: their strategy was to upgrade all the drives on one production line to new models, and then keep the removed old drives as spare parts for their remaining lines that still ran on the old drives 42 . This way, they immediately improved one line’s reliability and also created an emergency spares pool for the others, buying time to budget and schedule future upgrades. Such phased approaches can spread out costs and minimize risk just be sure to document any changes thoroughly, as you may have a mix of old and new drive types coexisting for some time.
· Consider Stopgap Measures (Rentals, Used Drives): If a critical drive fails and a new replacement will take months, there are a few temporary solutions to explore. Some service providers offer drive rentals or loaner units especially for larger drives or common sizes. For instance, during the 2022 shortage, certain vendors advertised rental drives from 7.5 kW up to 500 kW ready to ship on short notice to keep plants running 43 . While not a permanent fix, a rental drive can maintain production while you await the proper replacement. Another avenue is the secondary market: companies like resellers or equipment brokers might have refurbished or surplus units of your obsolete drive model. These can sometimes be procured faster than a new drive. The obvious caution with used drives is to ensure they are tested and guaranteed; also older drives that sat on a shelf for years may require capacitor reforming or preventative maintenance before you put them in service 44 . Engaging a reputable repair shop to refurbish a failed drive could also be an option they might replace damaged boards or components to get you back online. However, with very old or obscure models, repair may not be feasible due to lack of parts. Always weigh the cost and time of repair vs. replacement. If the drive is truly obsolete, investing in repairing it may be throwing good money after bad, whereas those funds could be put toward a modern drive that comes with full warranty and support.
· Training and Documentation: When introducing a new drive model into your facility, make sure the maintenance and engineering staff are up to speed on it. This includes having the manuals and
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programming software readily available (and backed up on your servers), and possibly training technicians on the new interface. Many newer drives have user-friendly features like mobile apps or web servers a great boon, but only if the team knows they exist and how to use them. Provide cheat-sheets for common tasks (like “How to jog the motor” or “How to read fault codes”) if the new drive’s HMI is different. During the first few weeks of operation, keep an eye on the new drive’s performance; enable any event logging features so that if a trip or issue occurs, you can trace whether it was due to a setup oversight or an underlying process problem. Being proactive with training and support will shorten the learning curve and build confidence that the new equipment is not a black box.
· Manage Backwards Compatibility in Controls: If the drive is integrated with a PLC or SCADA system, check if the control logic or communications need updates. For example, you might have to install a new Add-On Instruction or function block in the PLC program if the communication register mapping changed with the new drive. In one case, an engineer replacing obsolete drives noted that the PLC’s fault monitoring logic had to be adjusted because the new drive reported certain status bits differently than the old one. Small integration details like this are easy to miss but can cause headaches (e.g., a “Drive Healthy” bit that used to be high=OK might now be low=OK). Testing under real conditions is the only way to be sure all signals are handled properly. It’s helpful to involve a controls engineer during the retrofit if any doubt exists on the interfacing. They can implement any necessary changes to HMIs, alarm settings, or network configurations ahead of the swap so that the transition is seamless.
Real-World Impact: Downtime and Substitution Challenges
To put things in perspective, consider a few anonymized scenarios that have played out in industry:
· A food & beverage plant running 24/7 had an aging VFD on a critical conveyor that finally failed. The drive was an older model no longer sold, and lead time for the manufacturer’s new equivalent was 20 weeks. Every day that conveyor was down meant lost production of perishable goods. The maintenance team scoured distributors and managed to find a compatible drive from a different brand that could be shipped in 3 days. However, integrating this substitute drive came with challenges its control terminals and programming were unfamiliar, and the team spent extra time getting it tuned to the process. The line eventually restarted with minimal loss, but this fire-drill scenario prompted the company to re-evaluate all similar drives in the facility and accelerate plans to replace those near end-of-life. The lesson learned was to qualify second-source options in advance. By identifying a few drive brands/models that could work in their applications, they now have a contingency playbook if primary suppliers falter.
· A municipal water treatment facility had multiple pump VFDs of the same make and model, installed about 15 years ago. Over time, that model was discontinued by the OEM. When one drive blew a power module, the plant operators resorted to cannibalizing an old out-of-service drive (kept in their storage) to get the pump running again. This patchwork fix kept them going short-term, but it was clearly not sustainable. Running out of spares, they faced the very real risk that another drive failure would force a partial plant shutdown. In the end, the utility brought in a service contractor to retrofit all the pump drives to a current model in a staged manner. They scheduled one pump at a time to be taken offline, installed new drives (with new wiring and updated control integration), and verified performance before moving to the next thus maintaining treatment capacity throughout.
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This case highlights how “mixing and matching” parts from different generation drives, or cannibalizing old units, is a risky stopgap 45 46 . It might work once or twice, but it increases the odds of an unplanned outage. A planned retrofit, though initially costly, restored reliability and peace of mind.
· A printing/packaging company running legacy Lenze drives in its machines experienced frequent minor stoppages due to drive faults and lack of diagnostic info. Because those drives were obsolete, getting technical support was difficult and replacement parts were scarce. The company decided to invest in a modernization project: they retrofitted one production line with state-of-the-art drives (and upgraded the control system simultaneously), which required some mechanical modifications and operator retraining. During implementation, they split the project into phases to limit downtime for example, converting half the line’s drives during one maintenance window, and the rest later 47 48 . The outcome was very positive: the new drives significantly reduced the unwelcome downtime, improved product quality (by providing more consistent motor control), and gave operators better feedback through alarms and messages 49 50 . While the initial impetus was to solve the obsolescence headache, the company realized additional benefits in efficiency. This demonstrates that replacing obsolete drives is not merely a defensive cost it can also be an opportunity to boost performance and productivity with newer technology.
Practical Advice for Switching Models or Brands
For engineers and procurement professionals facing an obsolete VFD replacement, here is a consolidated checklist of advice:
· Do your homework on the replacement: Gather all specs of the old drive (power, voltage, overload rating, control method) and ensure the chosen new drive meets or exceeds them. Use the manufacturer’s cross-reference guides or talk to application engineers to select the right model and options. If switching brands, double-check motor compatibility (most modern drives can run standard AC motors, but if you have something specialized like a high-speed spindle or synchronous motor, verify the drive can handle it).
· Budget for the “extras”: When quoting a replacement drive, include the cost of any needed peripherals new fuses or circuit breaker (if the old drive size changed), mounting hardware, option cards, a programming cable, etc. It’s wise to also have the programming software and maybe a spare keypad or interface device in the budget. These small items can save time during commissioning. Also consider if you will keep a spare drive on the shelf; if the new model is critical, having one extra in inventory might be justified.
· Develop a test plan: Especially if replacing drives across multiple machines, test one installation thoroughly. Verify all I/O, interlocks, and performance under load. Capture parameter settings of the new drive as a template for others. If possible, run the new drive in parallel (or in a simulation mode) before fully cutting over for instance, some VFDs can be configured offline and even simulate the application to an extent. At minimum, bench-testing a drive with a spare motor can help familiarize technicians with its behavior.
· Update drawings and documentation: After installing the new drive, update electrical schematics, panel layouts, and parts lists to reflect the change. Label the drive clearly with its new model number
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(and firmware version). If any wiring was moved or repurposed, ensure the drawings note that. Future maintenance personnel will thank you. Also, keep a record of the old drive’s parameters and the new drive’s parameters (perhaps in a comparative sheet) in case troubleshooting is needed down the road.
· Mind safety and compliance: Replacing a drive is a good time to check that safety circuits and fault monitoring are working correctly. Many modern drives have built-in safe torque off (STO) functions or other safety-rated features. If applicable, integrate these according to the manufacturer’s guidelines rather than simply carrying over the old wiring scheme. Ensure that any lockout/tagout procedures and arc-flash labels are revised if the drive size or configuration changed significantly. From a compliance angle, if the new drive has different harmonic filters or EMC performance, confirm that the system still meets required standards (IEEE 519 for harmonics, etc.) most likely it will improve, but it’s worth noting.
· Communicate with stakeholders: Let operators and production supervisors know what to expect with the new drive. If there will be any noticeable differences (e.g. a drive display looks different or a motor ramps a bit differently), set expectations and incorporate any new operating instructions into SOPs. Often the differences are minimal, but clear communication ensures there are no surprises. If the new drive offers remote monitoring, for example, operations might benefit from being shown how they can see drive statuses from the control room, rather than physically walking to each unit.
In summary, tackling obsolete VFDs requires a mix of technical diligence and strategic planning. The technical side involves understanding the differences of the new vs. old drives and making the necessary adjustments for a smooth changeover. The strategic side involves timing the replacements to minimize impact and having contingency options when supply chains are uncertain.
Conclusion
Dealing with obsolete VFD models is a common challenge in today’s industrial landscape. As we’ve seen, manufacturers like ABB, Hitachi, Eaton, Lenze, and Yaskawa are continually updating their drive offerings and legacy models eventually enter retirement. The key for industrial users is to stay informed and proactive. By identifying obsolete drives in your systems and planning replacements (or securing spares) ahead of failure, you can avoid the costly downtime that unplanned breakdowns of unsupported models can cause. The recent supply chain crises only reinforce the importance of having flexible sourcing strategies and not waiting until the last minute to replace aging equipment.
Fortunately, for every obsolete VFD there is usually a modern equivalent available one that often brings enhanced features, better efficiency, and longer support life. Embracing these newer models, however, comes with the responsibility to manage differences in installation and operation. Engineers and technicians should leverage all available resources (manufacturer guides, expert advice, case studies like those discussed here) to ensure a successful transition. Whether it’s a one-for-one swap within the same brand or a switch to an entirely new vendor due to availability, thorough preparation and testing are your allies.
Obsolescence may be inevitable, but it doesn’t have to be disruptive. With careful planning, crossdisciplinary coordination, and the lessons learned from others’ experiences, you can turn the challenge of VFD model replacement into an opportunity improving the reliability and performance of your systems for
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years to come. In the end, the goal is the same for everyone from plant engineers to procurement officers: keep the plant running safely, efficiently, and with minimal downtime, no matter what changes in the supplier’s catalog. By following the strategies outlined above, you’ll be well positioned to do exactly that, navigating the maze of obsolete drives and long lead times with confidence and clarity.
References
1. Contiweb BV “Obsolete Lenze drives” (Blog post, April 2022). Lenze’s 2017 announcement of 8200/9300/SMD series phase-out due to RoHS, and discussion of availability challenges and retrofit strategies 1 42 .
2. Marshall Wolf Automation “Product Update: Hitachi WJ200 Series” (Blog post by Theresa Hoffman, Feb 14, 2024). Details on Hitachi WJ200 discontinuation and WJ-C1 replacement, noting identical footprint and ease of transition 51 52 .
3. ABB “Sales ramp-down announcement: ACS550, ACH550 and ACQ550” (ABB PDF, rev. D, circa 2020). Official ABB notice that ACS580/ACH580/ACQ580 replace ACS550-series drives, with North America phase-out timeline in 2021 3 5 .
4. EDC Scotland “What’s the replacement for the ACS800 variable speed drive?” (Blog post, Nov 15, 2016). Explains ACS800 going obsolete, succeeded by ACS580/ACS880, and notes that obsolete drives remain available only as spares with extended lead times (~10 weeks) and higher cost 4 6 .
5. Reddit r/PLC thread “VFD Shortage, recommendations for alternatives” (mid-2022). Community discussion highlighting long lead times (one example: 40-week lead time for a ½ HP drive) and switching to alternative brands due to supply shortages 12 .
6. Stromquist & Company “VFD Supply Chain Update” (Blog post by Reid, May 22, 2023). Industry update on improving VFD availability in 2023, with lead times coming down to 48 weeks after prior constraints 15 .
7. Yaskawa Europe “Product Phase Out Announcement of A1000, V1000, J1000” (Official notice, Feb 24, 2023). Lifecycle change announcement stating these series will be discontinued by March 2024 and replaced by GA500/GA700 series 7 8 .
8. Davis Controls “Danfoss Eaton SVX9000 Replacement” (Technical note on daviscontrols.com, accessed 2025). Confirms Eaton SVX9000 drives are no longer available from Eaton and that Danfoss NXS series drives can be used as direct drop-in replacements (same programming, form, fit) 53 .
9. Wistex LLC “ACS580 vs ACS550 Key Differences & Why the ACS580 is the Right Replacement” (Blog post, May 8, 2025). Outlines differences between ABB ACS550 and newer ACS580, including note that ACS550 became obsolete and the ACS580 is physically larger in some cases 54 27 .
10. Onefinity CNC Forum “Hitachi WJ200 VFD Discontinued” thread (Jan 2024). Contains excerpt from Hitachi WJ-C1 manual on how to copy WJ200 parameters to WJ-C1 and notes on upward compatibility of WJ-C1 with WJ200 settings 22 24 .
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11. Lenze (Lenze AG) “Differences in the inverter control via CAN bus between 8200vector and 8400” (Technical document, Lenze, 2010). States that the Lenze 8200vector series “is replaced by the new 8400 series”, indicating the intended succession of product lines 16 .
12. Electronic Drives & Controls (EDC) “Case Study Upgrading an Obsolete Coating Line” (Case study, Nov 2021). Describes a project replacing 20-year-old drives and PLCs; highlights that obsolete drives with self-contained loops were causing downtime, and new PowerFlex drives + PLC reduced downtime and restored automatic control 49 40 .
1 11 42 Obsolete Lenze drives | Contiweb BV
https://www.contiweb.com/resource-center/obsolete-lenze-drives
2 19 20 21 51 52 Product Update: Hitachi WJ200 Series – Wolf Automation
https://www.wolfautomation.com/blog/product-update-hitachi-wj200-series/? srsltid=AfmBOorgG_X67rPK54KS8u6uS2LpyG9hu9JXzBrCOsZIq1iAHbNSKsdy
3 5 41 library.e.abb.com
https://library.e.abb.com/public/d08763f02cc4431c99831bac67288875/Sales_ramp-down_announcement_ACS550_rev_D.pdf
4 6 26 What’s the replacement for the ACS800 variable speed drive? | EDC Scotland Ltd
https://www.edcscotland.co.uk/blogs/news/whats-the-replacement-for-the-acs800-variable-speed-drive
7 8 9 30 31 A1000, V1000, J1000
https://www.yaskawa.eu.com/ac-drives/product-announcements/a1000_v1000_j1000
10 33 53 DANFOSS – EATON SVX9000 REPLACEMENT – Davis Controls
12 13 14 VFD Shortage, recommendations for alternatives : r/PLC
https://www.reddit.com/r/PLC/comments/vmb3wp/vfd_shortage_recommendations_for_alternatives/
15 VFD Supply Chain Update | Stromquist & Company
https://www.stromquist.com/blog/805/vfd-supply-chain-update
16 Difference_list_CAN_8200vec_8400_V10
https://download.lenze.com/AKB/English/201007480/Difference_list_CAN_8200vec_8400_V10.pdf
17 18 44 Lenze 8200 vector | PLCS.net – Interactive Q & A
https://www.plctalk.net/threads/lenze-8200-vector.76815/
22 23 24 38 Hitachi WJ200 VFD Discontinued – Spindle/VFD (Aftermarket) – Onefinity CNC Forum
https://forum.onefinitycnc.com/t/hitachi-wj200-vfd-discontinued/24797
25 [PDF] — Frequency-converter update from ACS 800 series to ACS 880 …
https://library.e.abb.com/public/8909962ae88a43ecb1adc7a2581f1a0c/ 9AKK107992A8679_ABB+MNS+ACS880+retrofit_EN_v4_Leaflet.pdf?xsign=Uyv5WN6t35rHoliSiq%2FwrlZLTjn6cwD1rl9O7uY7CvHcuETpg4rVsmut2Na3rvG3
27 54 ACS580 vs ACS550 Key Differences & Why the ACS580 is the Right Replacement – Wistex
https://www.wistexllc.com/blog/acs580-vs-acs550-differences-use-cases/? srsltid=AfmBOopfda1AAWHfRync1j3g0ajFJdOvvxLbKHtTtplWqbC5R3mr09ds
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28 29 36 37 ACS550_ACS580_Comparison_Guide_3AXD50000660681 Rev C.indd
https://library.e.abb.com/public/0c7d2044abf94581b007e2fdcbf61eef/ ACS550_ACS580_Comparison_Guide_3AXD50000660681%20Rev%20C.pdf
32 Yaskawa AC Drive Transition Guide: V1000 to GA500 – Innovative-IDM
https://innovativeidm.com/2021/02/08/yaskawa-ac-drive-transition-guide-v1000-to-ga500/
34 35 Eaton SVX and HVX Drives | DO Supply Blog
https://www.dosupply.com/tech/2021/12/27/eaton-svx-and-hvx-drives/?srsltid=AfmBOop63XNIHzOCoK36SPE94Cw82soEIhqbWP0kiRJl7wCS_dEZiR6
39 40 47 48 49 50 Case Study Upgrading an Obsolete Coating Line | Electronic Drives and Controls
https://electronicdrives.com/home/case-study-upgrading-obsolete-coating-line/
43 Variable Speed Drive Shortage – Inverter Drive Systems Ltd
https://www.inverterdrivesystems.com/variable-speed-drive-shortage
45 46 Preventing Downtime in 24/7 FMCG Production: A CASE STUDY
https://www.acorn-ind.co.uk/insight/case-study-preventing-catastrophic-downtime-in-247-fmcg-production-with-customsolutions/?srsltid=AfmBOoqmH1kMay9jvRAQNvgUzBvdb2wX6Ftz2_1aGHwoWqAXeqxcCSJ_
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Documents / Resources
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PRECISION ELECTRIC ACS550 Variable Frequency Drive [pdf] Instruction Manual ACS550, ACS800, ACH550, ACQ550, A1000, V1000, J1000, ACS550 Variable Frequency Drive, Variable Frequency Drive, Frequency Drive, Drive |