The Most Overlooked Preventative Maintenance Steps in Industrial Controls
Preventative maintenance keeps industrial control systems running smoothly — but not all maintenance tasks get the attention they deserve. Some are skipped because they seem minor. Others are ignored until a failure makes them impossible to miss.
The problem? Small oversights turn into major downtime. Here are some of the most overlooked maintenance steps — and how to fix them before they cause bigger problems.
1. Ignoring thermal inspections
Heat is one of the biggest threats to industrial controls. Over time, excessive temperatures wear down components, leading to insulation failure, contact degradation, and unexpected shutdowns. The problem? Not all overheating is visible, and by the time signs appear, damage is already happening. Here’s how to beat the heat:
- Routine thermal imaging scans help detect overheating before it causes failure.
- Proper ventilation and cooling inside control panels reduce excessive heat buildup.
- Any overheated or discolored components should be replaced immediately to prevent further damage.
2. Overlooking loose connections
Vibration, temperature fluctuations, and repeated electrical loads cause connections to loosen over time — and it causes more than just a simple reliability issue. Loose terminals increase resistance, generating heat that could lead to burned contacts and potential fire hazards. Consider these simple steps to prevent it:
- Scheduled torque checks help you make sure all terminals and connections stay secure.
- Signs of overheating, like discoloration or melted insulation, indicate a problem that needs immediate attention.
- Locking mechanisms or vibration-resistant fasteners help prevent loosening in high-motion environments.
3. Neglecting firmware updates
Control systems rely on software as much as hardware, yet firmware updates are still frequently overlooked. Outdated firmware can cause system inefficiencies and security vulnerabilities, among other critical problems. Manufacturers release updates to improve efficiency and protect against cyber threats. Here’s how to capitalize on bug fixes and system updates:
- Checking for OEM firmware updates should be part of routine maintenance.
- Scheduled updates prevent unplanned disruptions and keep systems running smoothly.
4. Skipping filter replacements
Cooling fans and ventilation systems protect control panels from excess heat, but only if air can flow properly. Clogged filters restrict airflow, allowing dust to settle on components, reducing efficiency, and increasing the risk of failure. To keep dust at bay (and out of your control systems), follow these simple steps:
- Air filters in control cabinets and enclosures should be replaced on a frequent schedule.
- Fans and ventilation pathways need regular inspection to remove dust and debris.
5. Grounding issues
Poor grounding creates everything from erratic sensor readings to complete system malfunctions. Over time, grounding connections corrode or loosen, affecting signal stability and causing electrical noise interference. Follow these simple maintenance tips to maintain the integrity of your grounds:
- Verify ground continuity with periodic testing and inspections.
- Bonding connections must be clean, free of oxidation, and securely fastened.
- Grounding filters or isolation transformers help reduce electrical noise in sensitive applications.
Expert repairs keep your control systems reliable.
Even with regular maintenance, wear and tear are inevitable. And when your equipment needs repair, accuracy matters. At GES, we specialize in diagnosing and servicing industrial electrical components with expert precision. Whether it’s reconditioning terminals, replacing worn contacts, or upgrading firmware, we keep your systems online and efficient.
Don’t forget that now through the end of February, we’re making it even easier to maintain vital systems with 10% OFF single repairs or 15% OFF 3+ repairs of Allen-Bradley industrial control products!
