In this guide
Most panel failures give warning first: a hot connection, a weak power supply, a clogged filter. A short routine of checks finds them. Only qualified persons should open live panels, and all work should follow your site's isolation and permit procedures.
Suggested schedule
| Frequency | Check |
|---|---|
| Monthly | Look and listen: fan operation, filters, alarm lights, unusual smells or discolouration, door seals and condensation |
| Quarterly | Measure 24 V DC supply output and check for ripple or sag under load. Check panel temperature against equipment limits |
| Yearly | Clean the inside with a vacuum, not compressed air that can blow dust deeper. Re-tighten power terminals to the manufacturer's torque values. Thermal image the panel under normal load |
| Yearly | Back up PLC programs, HMI applications and drive parameters, and confirm the backups restore |
| Yearly | Check UPS and PLC battery condition and replace to the manufacturer's schedule |
| After any change | Update drawings and labels, and update the spares register |
What to look for
- Heat: discoloured insulation, hot terminals on a thermal image, or a panel that runs hotter than before
- Dust and moisture: blocked filters, dust on heat sinks, rust or water marks, condensation
- Loose or damaged wiring: terminals that have moved, cracked insulation, loose shield connections
- Power supplies: output voltage below nominal, ripple, or a supply that is warm to the touch and near its rating
- Earthing: loose or corroded earth connections, which cause random faults
Keep records
Note what you measured and when. A 24 V supply that reads a little lower each quarter, or a panel temperature that creeps up, tells you what to fix before it fails. Pair the checks with a spares register so you know what to replace and what you hold.
If a check turns up a part that is ageing or discontinued, send us the order number and we will check availability and lead time.