3 Signs Moisture Has Damaged Your Automation Equipment
Moisture is one of the most underestimated threats in industrial environments. Whether it comes from high humidity, washdown areas, condensation, leaks, or poor cabinet sealing, moisture can silently damage automation equipment long before a full breakdown happens.
The good news: most moisture-related failures give warning signs first. If you catch them early, you can avoid costly downtime, unexpected replacement, and safety risks.
Here are 3 clear signs moisture has already started damaging your automation equipment and what you should do next.
1) Corrosion, Rust, or Discoloration on Components
One of the most visible signs of moisture damage is corrosion. Even small amounts of humidity can trigger oxidation, especially on:
- Terminal blocks and connectors
- PLC I/O modules and pins
- Power supply contacts
- Relay sockets and contactors
- Cabinet hinges and grounding points
What it looks like:
- Green or white residue on copper terminals
- Rust spots on metal parts
- Dark stains or discoloration on boards
- Powdery buildup near screws and connections
Why it matters:
Corrosion increases electrical resistance and weakens contact points. Over time, this leads to:
- Unstable signals
- Random alarms and faults
- Overheating
- Complete failure of the device
Quick check: Open the panel and inspect the lowest point inside the cabinet. Moisture often collects there first.
2) Intermittent Faults and Random Downtime
Moisture damage doesn’t always cause an immediate shutdown. Often, it shows up as intermittent problems that are hard to troubleshoot.
Common symptoms include:
- PLC or HMI resets without a clear cause
- Communication errors (Ethernet, Profibus, DeviceNet, etc.)
- Sensors giving unstable readings
- Drives tripping unexpectedly
- Relays clicking or chattering
- Unexplained short circuits or blown fuses
Why it happens:
Moisture creates unwanted electrical paths and weak insulation. That means equipment may behave normally one moment, then fail the next, especially when temperature changes create condensation.
If your system keeps failing “randomly,” moisture could be the real root cause.
3) Condensation Inside Panels or Fogged Windows
If you see water droplets, fog, or dampness inside the cabinet, moisture is already present and damaging your equipment.
Signs to look for:
- Fogged panel windows
- Water marks inside enclosures
- Damp cable entries or gland seals
- Wet insulation around wiring
- Condensation after shift changes or temperature drops
Why it matters:
Condensation is especially dangerous because it can happen even in “dry” facilities. It usually occurs when:
- Warm air enters a cabinet
- Temperature drops quickly
- Moisture turns into water on cold surfaces
This is why automation equipment often fails after weekends, overnight stops, or seasonal changes.
What To Do If You Suspect Moisture Damage
If you notice one or more of these signs, don’t wait for a full failure. Early inspection can save your equipment and reduce downtime.
Recommended actions:
✔️ Inspect terminals, connectors, and PCB areas for corrosion
✔️ Check door seals, cable glands, and ventilation points
✔️ Verify cabinet heaters, filters, and panel cooling systems
✔️ Measure insulation resistance where applicable
✔️ Clean and re-terminate affected connections
Repair & Inspection Services
Moisture damage can start small, but it often ends in costly breakdowns. If you’re seeing corrosion, intermittent faults, or condensation inside your panels, it’s time to act.
Need help checking or restoring your automation equipment?
We offer professional repair & inspection services to identify moisture-related issues early, restore performance, and help protect your system from future failures.
