When we think of equipment failure, we often blame age, wear, or faulty parts. But the real culprits behind many breakdowns are less obvious—and far more dangerous. Dust, heat, and vibration are silent killers of industrial electronics. These environmental hazards work behind the scenes, slowly degrading performance until one day… the system fails.
If you’re not actively protecting your industrial electronics from these threats, you’re risking costly downtime and expensive repairs. The good news? You can take steps now to prevent equipment failure and extend the life of your assets.
The Triple Threat to Industrial Electronics
Dust may seem harmless, but it’s far from it. When it accumulates on circuit boards, fans, or power supplies, it traps heat and blocks airflow. It also attracts moisture, which accelerates corrosion. In VFDs, dust buildup combined with oil and metal particles can lead to stray current paths and overheating—often resulting in catastrophic failure.
Heat is another major factor in electronics failure. Excessive temperatures can damage internal components like capacitors, resistors, and chips. Overheating is especially common in poorly ventilated environments or when dust clogs cooling systems. Over time, thermal stress weakens solder joints and causes materials to expand and contract, which leads to cracks and connection failures.
Vibration, often overlooked, causes just as much harm. It loosens wires and screws, damages solder joints, and shortens the lifespan of sensitive components like encoders and I/O cards. Devices exposed to continuous motion or poor mounting can develop internal fractures that lead to inconsistent performance or total shutdown.
Why You Should Care
These environmental threats don’t just damage your equipment—they cost you money. Downtime can halt production, delay shipments, and increase labor costs. Repairing or replacing industrial electronics is expensive, especially when the failure could have been prevented with proper maintenance.
Equipment Failure Prevention Tips
If your business depends on electronics (and whose doesn’t?), implementing a proactive maintenance plan is essential. Here’s how to fight back:
- Schedule regular cleanings: Use compressed air or a non-static vacuum to remove dust from fans, vents, and components. Keep filters clean and replace them as needed.
- Control your environment: Maintain safe temperature ranges in equipment areas. Install proper ventilation and consider using sealed or fanless enclosures for sensitive electronics.
- Monitor for vibration: Use shock absorbers, dampers, or isolation mounts for equipment in high-vibration zones. Regularly inspect connectors and hardware for signs of loosening.
- Inspect for moisture: If your facility deals with humidity or water exposure, use conformal coatings and sealed housings. Moisture combined with dust creates sludge that leads to corrosion and shorts.
- Choose the right components: Invest in ruggedized electronics designed for industrial environments. Components with built-in diagnostics can alert you to early-stage issues.
Call ACS Industrial for Repairs and Service to Help Extend the Life of Your Industrial Electronic Equipment!
Knowing how to keep industrial electronics in operation can be tough, but you don’t have to do it alone. At ACS Industrial Services, we specialize in preventative maintenance and repair services for industrial electronic equipment.
With over 20 years of experience, ACS is a leading industrial repair service provider when things break. We repair many different components of machinery across various makes and models. We provide a rapid turnaround time. Most repairs are back in your hands within 7-15 business days, with our Rush Repair Service typically shipping in just 3-5 business days.
Contact us for a FREE evaluation and a no-obligation quote, or call (800) 605-6419.