Long-term Storage

Capacitor Reforming for ABB Drives

Service Policy and Procedures Form 50.20-NM12 (418) Form 50.20-NM12 (323)

Guide for capacitor reforming in ACS250/255, ACH/AYK550,

and ACH/AYK580
Overview
You need to reform, or re-age, Electrolytic DC capacitors in the drive DC link if the module has been non-
operational for a certain amount of time. Without reforming, capacitors can be damaged when the drive starts to
operate. The manufacturer recommends you reform the capacitors once a year or once every 3 years depending on
the drive module type.

Equipment
• Digital multimeter: Fluke model 179 or equivalent
• DC power supply: Tektronix/Keithley model 2260B-800-1 or equivalent

ACH/AYK550 and ACS250/255

Checking the drive age
Check the serial number shown on the drive labels for the date of manufacture. The serial number defines the year
and week when the drive was manufactured. There are two formats of serial numbers. Check which format the
drive has and determine the date of manufacture:
• 8 digits: YWWXXXXX
• Y = year, for example, 6, 7, 8, 9, A, B... = 2006, 2007, 2008, 2009, 2010, 2011...
• WW = week
• 10 digits: XYYWWXXXXX
• YY = year, for example, 06, 07, 08, 09, 10... = 2006, 2007, 2008, 2009, 2010...
• WW = week
Reforming time
The intermediate circuit (DC link) of the drive is connected to its nominal voltage for the appropriate amount of
time to reform the capacitors. See Figure 1 for the required reforming time, which depends on how long the drive
has been non-operational.

LD32163

Figure 1 - Capacitor reforming time, ACH/AYK550 and ACS250/255

 Form 50.20-NM12
Issue date: 03/06/2023

Reforming with power on

Use this method of capacitor reforming if the drive has been non-operational for less than 2 years:
• Switch on the power to the drive for the amount of time listed in Figure 1, Method 1.

Do not load the drive while the reforming is in progress.

The drive automatically initiates its capacitors, after which it is ready for use.

Reforming with external DC power supply

Use this method of capacitor reforming if the drive has been non-operational for 2 years or longer:
1. Ensure that the drive module is disconnected from all possible power sources, including all AC and DC inputs
or outputs.
2. Check that the installation is de-energized:
• Use a multimeter with an impedance of at least 1 MΩ.
• Ensure that the voltage between the drive input power terminals, U1, V1, and W1, and the grounding
terminal, PE, is close to 0 V.
3. Create the reforming circuit shown in Figure 2 and connect it to the terminals of the drive module as shown in
Table 1. An external resistor is not necessary if the DC power supply has an adjustable current limiter.

LD32164

Figure 2 - External DC power supply reforming method, ACH/AYK550 and ACS250/255

Table 1 - Drive connections based on drive series

Drive series Phase A Phase B Phase C

marking marking marking
ACH/AYK550 U1 V1 W1
ACS250/255 L1/L L2/N L3

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Form 50.20-NM12
Issue date: 04/06/2023

4. Switch on the reforming circuit for the time shown in Figure 1, Method 2.

Limit the reforming current to 100 mA maximum.

Only a qualified techinican familiar with medium voltages and the operation of a
variable frequency drive (VFD) can conduct this work.

I f the DC power supply does not have an adjustable current limiter, increase the voltage gradu-
ally from 0 to the nominal voltage value. Regulated DC power with active current limiting:
• Output current: 0.1 ADC to 1 ADC, maximum 100 mA during reforming.
• Output voltage: adjustable from 0 VDC to 1,000 VDC. An appropriate voltage during
reforming is 1.35 Ux to 1.45 Ux. Ux denotes the nominal AC voltage of the drive.

5. Switch off the reforming circuit.

6. Wait for 5 min to let the drive DC capacitors discharge.
7. Measure that the voltage of the DC terminals of the drive is close to 0 V.
8. Disconnect the reforming circuit from the drive.

ACH/AYK580 drive series

Checking the drive age

Check the serial number shown on the drive labels for the date of manufacture. The serial number defines the year
and week when the drive was manufactured. There are three formats of serial numbers. Check which format the
drive has and determine the date of manufacture:
• 7 digits: 3260034
• 3 = manufacturing year, 2003
• 26 = manufacturing week
• 0034 = running manufacturing number
• 8 digits: 14250125
• 1 = manufacturing country (1 = Finland)
• 4 = manufacturing year, 2004
• 25 = manufacturing week
• 0125 = running manufacturing number.
• 10 digits: 1173200725
• 1 = manufacturing country
• 17 = manufacturing year, 2017
• 32 = manufacturing week
• 00725 = running manufacturing number

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 Form 50.20-NM12
Issue date: 03/06/2023

Reforming time
The intermediate circuit (DC link) of the drive is connected to its nominal voltage for the appropriate amount of
time to reform the capacitors. See Figure 3 for the required reforming time, which depends on how long the drive
has been non-operational. Use line b for ACH/AYK580.

LD32165

Figure 3 - Capacitor reforming time, ACH/AYK580

Reforming with power on for 30 min

Use this method of capacitor reforming if the drive has been non-operational for less than 3 years:
1. Switch on the power to the drive for 30 min.

Do not load the drive while the reforming is in progress.

The drive automatically initiates its capacitors, after which it is ready for use.

Reforming with external DC power supply

Use this method of capacitor reforming if the drive has been non-operational for 3 years or longer:
1. E
 nsure that the drive module is disconnected from all possible power sources, including all AC and DC inputs
or outputs.
2. Check that the installation is de-energized:
• Use a multimeter with an impedance of at least 1 MΩ.
• Ensure that the voltage between the drive input power terminals, U1, V1, and W1, and the grounding
terminal, PE, is close to 0 V.
• Ensure that the voltage between the drive DC terminals, UDC+ and UDC-, and the grounding terminal,
PE, is close to 0 V.
3. C
 reate the reforming circuit shown in Figure 4 and connect it to the DC terminals of the drive module.
An external resistor is not needed if the DC power supply has an adjustable current limiter.

4 Johnson Controls
Form 50.20-NM12
Issue date: 04/06/2023

LD32166

Figure 4 - External DC power supply reforming method, ACH/AYK580

4. Switch on the reforming circuit for the time shown in Figure 3.

Limit the reforming current to 500 mA maximum.

Only a qualified techinican familiar with medium voltages and the operation of a
VFD can conduct this work.

I f the DC power supply does not have an adjustable current limiter, increase the voltage gradu-
ally from 0 to the nominal voltage value. Regulated DC power with active current limiting:
• Output current: 0.1 ADC to 1 ADC, maximum 100 mA during reforming.
• Output voltage: adjustable from 0 VDC to 1,000 VDC. An appropriate voltage during
reforming is 1.35 Ux to 1.45 Ux. Ux denotes the nominal AC voltage of the drive.

5. Switch off the reforming circuit.

6. Wait for 5 min to let the drive DC capacitors discharge.
7. Measure that the voltage of the DC terminals of the drive is close to 0 V.
8. Disconnect the reforming circuit from the drive.

Johnson Controls 5
100 JCI Way, York, Pennsylvania USA 17406 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2023 www.johnsoncontrols.com All Rights Reserved
Form 50.20-NM12 (323)
Issue Date: March 6, 2023
Supersedes: 50.20-NM12 (418)