Smarter maintenance with sine-wave filter monitoring
Get more from your drives with integrated sine-wave filter monitoring – now available in Danfoss VLT® premium drives. As part of our enhanced condition-based monitoring (CBM) suite, this new feature allows for early detection of capacitor degradation in sine-wave filters for VFDs, reducing the risk of breakdowns and unplanned downtime.
By tracking key filter conditions from inside the drive – no external sensors required – your maintenance team can respond before issues escalate. That means better protection, longer equipment lifetime, and safer operation.
What is sine-wave filter monitoring and how does it work?
Sine-wave filter monitoring is a condition-based maintenance variable frequency drive (VFD) function that uses edge computing in Danfoss drives to supervise filter capacitor health. Capacitors in sine-wave filters VFD systems degrade over time, and if left unchecked, this can lead to hazardous failures or damage to motors and drives
By establishing a baseline at startup, the drive then checks filter capacitance every two days. When deviation from the baseline exceeds a threshold, the system sends a warning or alarm – giving your team time to take action and replace capacitors before failure occurs.
This form of VFD filter monitoring is fully embedded in the drive logic, which eliminates the need for additional infrastructure while enabling smarter service planning.
What are the benefits of sine-wave filter monitoring?
Proactive protection: Get early warnings about capacitor wear so you can avoid breakdowns.
Easy to deploy: Fully embedded in the drive – no external sensors needed.
Simple retrofit: Works with both new and existing sine-wave filter VFD setups.
Lower total cost of ownership: Less maintenance effort, fewer surprises, longer equipment life.
Why monitor sine-wave filters?
Sine-wave filters are used to smooth the voltage waveform from VFDs, making them essential in demanding environments or sensitive motor applications. The integrated monitoring function adds an extra layer of reliability to these use cases.
By implementing VFD filter monitoring, engineers can better predict potential points of failure and avoid unscheduled downtime. This is especially critical in industries such as chemical, oil and gas, mining, marine, or water and wastewater, where motors run continuously and access for inspection is limited.
Applications that benefit most include:
Long cable runs: Reduce voltage overshoot and protect motor insulation
Retrofit scenarios: Use modern drives with older motors safely
EMI-sensitive environments: Reduce electromagnetic interference in hospitals, labs, and studios
High-performance systems: Minimize torque ripple in servo motors and high-speed spindles
Multiple motor setups: Ensure consistent voltage quality across all motors
Motors with reduced insulation: Prevent premature insulation failure
Special motor types: Protect motors with weak winding or high-frequency operation
Our enhanced condition-based monitoring capabilities, including sine-wave filter monitoring, empower our customers to move from reactive to proactive maintenance strategies. By detecting potential issues early, we help them minimize downtime, reduce maintenance costs, and improve the overall reliability of their operations
Motor condition monitoring for remote locations
CBM is especially suitable for remote locations or devices that are difficult to access. With permanent monitoring, potential faults can be detected and addressed before they result in motor failure and production downtime. By taking maintenance strategies to the next level with CBM, industries can increase their application uptime, reduce maintenance costs, and enhance overall operational efficiency.
FAQs about sine-wave filter monitoring
Contact our expert
Do you have a question about sine-wave filter monitoring?
Get in touch with our expert, John Bargmeyer, for the answers you need. Submit your queries below to get in touch with John for an informal discussion.
Explore more opportunities with CBM
Refrigeration systems preserve apple quality using VSDs with integrated condition monitoring and DrivePro Remote Monitoring service
ITALY: At Rivoira Group, VLT® drives with built-in condition-based monitoring help preserve fruit perfectly by ensuring utterly reliable refrigeration.
Driving maximum uptime in aseptic pharmaceutical production
DENMARK: A leading global pharmaceutical company was determined to find an intelligent HVAC solution to prevent downtime with real-time system monitoring and customizable instant alarms. Plus, the solution needed to fit within the organization’s ambitious digitalization strategy. The solution: Danfoss VLT® HVAC Drive FC 102 with integrated condition-based monitoring.
Brewing up real change at HEINEKEN
NETHERLANDS: HEINEKEN understands that to meet demand, its production line must always be up to the task – with all assets expected to deliver a consistently reliable and excellent performance. At Den Bosch brewery, the tough working environment posed several challenges. The solution was an upgrade using drives with integrated condition-based monitoring.
Highlighted products
Danfoss products with the sine-wave filter monitoring function
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VLT® AQUA Drive FC 202 controls all types of pumps and comes equipped with a cascade controller.
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This tough and savvy FC102 drive enhances pump and fan applications in building management systems, and runs outdoors in most climates.
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The VLT® AutomationDrive FC 301 / FC 302 is designed for variable speed control of all asynchronous motors and permanent magnet motors. It comes in a standard version (FC 301) and an advanced high dynamic version (FC 302) with additional functionalities.
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FC 103 is dedicated to controlling compressors, pumps and fans for significant energy savings in refrigeration plants.
