New software functionality turns Danfoss VLT® drives into smart sensors that predict maintenance needs and increase uptime

Danfoss VLT® Condition-based Monitoring

New software functionality turns Danfoss VLT® drives into smart sensors that predict maintenance needs and increase uptime

By: Danfoss

Danfoss VLT® Condition-based Monitoring named finalist in 2020 AHR Expo Innovation Awards 

Danfoss VLT® Condition-based Monitoring is a new licensed software function for the Danfoss VLT® drives platform that allows users to employ the drive as a smart sensor. With condition-based monitoring, the drive monitors activity beyond it, gathering data from multiple sources to generate vital, real-time insights to better understand what is happening in the entire system, enable real-time early detection, and minimize unplanned and costly downtime. 

This new software functionality embeds monitoring functions in the drive, such as monitoring of motor stator winding conditions, mechanical-vibration monitoring, and load-envelope monitoring with or without a connection to the cloud or PLC. Users can set various thresholds and automatically or manually determine the baseline for monitoring with different methods in accordance to relevant standards and guidelines. 

For example, the Danfoss VLT® HVAC Drive’s motor winding condition monitoring function allows users to shift from corrective maintenance of faulty motors to detecting motor isolation faults at an earlier stage when they can be handled during scheduled maintenance. This eliminates unwanted and potentially costly machine downtime caused by shorted motors windings. Load-envelope monitoring compares the actual load curve to the initial values determined during commissioning. The Danfoss VLT® HVAC Drive allows users to detect unexpected operating conditions, for example leakages or clogs in an HVAC system. When a part has worn out, the load curve changes compared to the initial baseline, and a maintenance warning is triggered allowing the user to quickly and effectively remedy the issue. 

“Using variable frequency drives to monitor conditions in real time allows maintenance personnel to predict failures in HVAC equipment connected to the drive,” said Mark Hansen, US HVAC sales director, Danfoss Drives. “This helps to accommodate equipment replacement or repair before the equipment fails to prevent undesirable downtime and interruption of service. With the ability to connect to cloud-based services and PLCs, data monitoring of the conditions makes it easier for building management staff to spot trends in maintenance hot spots and better allocate maintenance staff time.” 

Danfoss VLT® Condition-based Monitoring was named a finalist in the Building Automation category of the 2020 AHR Expo Innovation Awards.  

Danfoss engineers advanced technologies that enable us to build a better, smarter and more efficient tomorrow. In the world’s growing cities, we ensure the supply of fresh food and optimal comfort in our homes and offices, while meeting the need for energy-efficient infrastructure, connected systems and integrated renewable energy. Our solutions are used in areas such as refrigeration, air conditioning, heating, motor control and mobile machinery. Our innovative engineering dates back to 1933 and today Danfoss holds market-leading positions, employing 27,000 and serving customers in more than 100 countries. We are privately held by the founding family. Read more about us at


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