Industry News & Updates

As temperatures drop and winter conditions arrive, industrial maintenance teams face added challenges in keeping equipment running reliably.

While production demands often remain high, colder temperatures, moisture, and condensation can strain industrial electronics, particularly in unheated factories, external control cabinets, warehouses, and exposed operating environments.

For manufacturers, an unexpected drive failure, power supply fault or PLC malfunction can quickly become more than a maintenance issue. It can lead to lost production, emergency repairs, extended downtime, and added costs.

Winter reliability isn't simply about responding to equipment failures. It's about understanding the risks and taking preventative action before problems develop.

How Cold Weather Affects Industrial Electronics

Industrial automation equipment is designed to operate within specified environmental conditions. However, equipment exposed to temperatures outside those limits, rapid temperature changes, or excessive moisture may become less reliable.

Some of the most vulnerable components include:

· Variable-speed drives and servo drives

· PLCs and control modules

· Industrial power supplies

· HMIs and operator panels

· Industrial PCs

· UPS systems and backup batteries

· Communication and network equipment

Cold temperatures alone aren't always the biggest concern. In many industrial environments, moisture and condensation pose a greater risk.

Condensation: The Hidden Winter Problem

Condensation forms when warm, moisture-laden air contacts colder surfaces.

In industrial environments, this can occur inside electrical cabinets, particularly where equipment experiences significant temperature fluctuations.

Over time, moisture can contribute to:

· Corrosion on electronic components and connections

· Insulation deterioration

· Electrical leakage and short circuits

· Intermittent control system faults

· Premature component failure

These problems may not always cause an immediate breakdown.

Instead, equipment may begin experiencing intermittent faults that become increasingly difficult to diagnose.

Preventative Action

Maintenance teams should check cabinet seals, enclosure heaters, ventilation arrangements, and signs of moisture ingress as part of their winter maintenance routines.

Environmental controls should always follow the equipment manufacturer's recommendations.

Power Supplies and Backup Systems

Industrial power supplies are essential to the operation of control systems.

A power supply failure can affect multiple connected devices, including PLCs, HMIs, communication modules and sensors.

Winter conditions may also expose weaknesses in ageing UPS systems and backup batteries, particularly where equipment is operating outside its specified temperature range.

Maintenance teams should review:

· Power supply condition and operating environment

· Signs of overheating, corrosion or deterioration

· UPS battery health

· Backup power availability

· Replacement part availability

A relatively small power supply can become a significant operational risk if a replacement is unavailable when required.

Drives, Motors and Control Systems

Variable-speed drives and motor control equipment play a critical role in industrial production.

Temperature changes, inadequate ventilation and moisture exposure can affect electronic components and contribute to operational faults.

However, maintenance teams should also consider the wider operating environment.

An intermittent drive fault may not necessarily indicate a failed drive. Issues involving electrical connections, cooling, moisture ingress or the associated motor should also be investigated.

Identifying the underlying cause is important before deciding whether to repair or replace equipment.

The Importance of Critical Spares During Winter

One of the greatest risks associated with an unexpected breakdown is discovering that the replacement component is unavailable.

Some industrial automation products are available from stock.

Others may have extended lead times, be supplied only on an Order on Request basis or have been discontinued by the original manufacturer.

For business-critical equipment, maintenance teams should know:

· Which components are essential to production

· Whether suitable replacement parts are held in stores

· Whether existing spares have been checked for compatibility

· Which components are obsolete or difficult to source

· Whether repair or refurbishment is a viable alternative

Having the right replacement available can significantly reduce the time required to restore production.

Repair or Replace?

When industrial electronics fail, replacement is not always the most practical option.

Depending on the equipment, the nature of the fault and the availability of suitable components, repair or refurbishment may offer a cost-effective alternative.

This can be particularly valuable where:

· Original equipment has been discontinued

· Replacement lead times are extended

· The equipment is part of an older production system

· A complete system upgrade would be disproportionately expensive

· The existing component can be economically repaired

Repairing industrial electronics can also extend equipment life and reduce unnecessary electronic waste.

However, repair suitability should always be assessed against equipment condition, operational requirements and safety considerations.

Preparing for Winter Reliability

A practical winter maintenance review should include:

1. Inspecting control cabinets for moisture and condensation.

2. Checking enclosure heating and ventilation systems.

3. Reviewing the condition of power supplies and backup batteries.

4. Investigating recurring or intermittent equipment faults.

5. Confirming critical spare availability and compatibility.

6. Identifying obsolete components and potential sourcing difficulties.

7. Reviewing outstanding repairs before they become urgent.

These activities cannot eliminate every unexpected failure, but they can help reduce avoidable risks.

How Ralakde Can Help

Ralakde supports manufacturers and industrial businesses with a range of industrial automation supply and repair solutions, including:

· New, surplus and obsolete industrial automation components

· Industrial electronics repairs and refurbishment

· Global sourcing of difficult-to-find parts

· Replacement PLCs, drives, HMIs and power supplies

· Critical spare supply

· Bonded and consignment stock solutions

· Inventory and obsolescence solutions

With operations supporting customers across the UK, Europe and the USA, Ralakde helps businesses access the components and repair solutions needed to maintain their industrial equipment.

Final Thought

Winter reliability isn't just about protecting equipment from cold weather.

It's about understanding the operating environment, identifying vulnerable components and ensuring maintenance teams have access to the right support when equipment fails.

Because the costliest winter breakdown may not be the failure itself. It may be discovering that the replacement part isn't available.

Need a replacement industrial automation component or repair solution?

Contact Ralakde to discuss your requirements. www.ralakde.com