Unplanned industrial downtime is alarmingly commonplace across the UK and Europe. Each incident can cause major disruption, significant additional costs, and lead to thousands of pounds of lost revenue.
One of the most common causes is the overheating of electrical systems that control production lines. We consider why using specialist service engineers for the installation, commissioning and maintenance of specialist cooling equipment can reduce the likelihood of expensive equipment failure and production breakdowns.
Why Use Specialist Service Engineers for Your Industrial Cooling Units
In the last three years, more than 80 percent of industrial businesses in the UK and Europe experienced unplanned production downtime, according to recent research by IDS-INDATA. Each incident lasted around four hours.
Unfortunately, software and systems failures are cited as one of the leading causes of production line equipment breaking down.
Clearly these statistics are concerning, particularly given how reliant industries are now on sophisticated electrical systems.
Perhaps it’s not surprising, given that industrial environments are hostile spaces for electrical equipment; their components don’t react well to high levels of moisture, dust, and heat in the atmosphere. But the number of failures also points to the need for both the correct installation/commissioning of systems, and regular, expert maintenance.
Enclosures house sensitive componentry like PLCs, drives, and other electronics that keep production lines running. They are designed to protect and maintain favourable operating conditions for the circuitry to function at optimum levels, providing it with physical protection from both atmospheric pollutants and physical damage. This need to create a sealed enclosure within which the electrical equipment can function needs to be balanced with the equally important requirement for optimum temperature management. Indeed, one of the critical factors in creating a ‘protective environment’ for this electrical equipment is effective climate control.
All electrical circuitry generates heat as a by-product of its activities, and this heat needs to be removed. Plus, of course, there is the ambient heat of the environment in which the equipment is sited. Maintaining a stable temperature within an enclosure ensures that electrical drives etc. can work to their full potential, thereby ensuring that the production equipment it controls can operate at high speed. All this can affect productivity and turnover; the faster a pallet-wrapping machine works, for example, the more goods can be shipped.
As a rule of thumb, an increase of 10°C can halve the life expectancy of electronic components, hence the need to use specialist electrical cooling units to dampen down any rises in temperature and ensure that all the electrical circuitry remains within its optimal temperature ranges.
Do You Need Specialised Knowledge & Expertise to Service Enclosure Cooling Equipment?
While general HVAC engineers play a vital role in many building services, the installation, commissioning, and ongoing maintenance of specialist industrial cooling equipment require a more tailored approach. Engaging manufacturer-trained service engineers ensures that these complex systems are installed and maintained to the highest standards, optimising performance, reliability and longevity.
For example, Rittal service engineers have an intimate knowledge of all of their cooling equipment. This expert knowledge ensures that the engineer can quickly and accurately pre-empt or diagnose issues and implement a solution that is tailored to the unique demands of that particular industrial environment. An automotive production line has very different requirements to, say, a food processing plant.
The team uses specialist software to identify any underlying problems and assess the future risk of potential faults; for example, how often a compressor has been running since the last service. If it has been running close to 100 percent of the time then it suggests that the cooling unit is overloaded and may need to be upgraded or it may fail without warning.
In addition, the diagnostic software can even indicate how often an enclosure door has been opened. Opening the door allows dirty air to be pulled into the enclosure, and this will gather in switchgear/connection points, potentially leading to short circuits or blocking on-board fans.
How Important is Correct Installation & Commissioning of Enclosure Cooling Units?
Rittal’s cooling units are extremely reliable, self-contained, and designed to be easy to install and commission. They also come with an instruction manual and we have a helpline available to answer any questions. However, there have been times when we have been called out to investigate problems that arise from oversights that have occurred during installation - such as improper wiring or a lack of earthing. Unfortunately, if these problems are not rectified before a system is commissioned then they can cause considerable damage to the cooling unit.
Furthermore, oversights during the installation of a cooling unit can impact on the future performance and efficiency of the equipment. For example, if the fitting clips on the unit are not properly adjusted there may not be a strong seal between the cooling unit and the enclosure. This can mean moisture is drawn into the enclosure from the surrounding air, which can lead to condensation forming inside the cabinet and lead to electrical failures.
Hence why we always recommend the commissioning (and ideally the installation itself) is done by a specialist service engineer.
What is Meant By Optimal Efficiency & Performance?
Industrial cooling units are designed to operate under very different conditions to residential or commercial HVAC systems.
As indicated, electrical componentry works most efficiently within closely defined temperature parameters – the factory setting for Rittal cooling units, for example, is set at 35oC. If this setting is changed once the unit is installed then it can affect the system’s efficiency and, again, result in condensation within the enclosure.
Equally, cooling equipment consumes considerable quantities of energy. If the unit temperature settings are altered they can add unnecessarily to its electricity consumption and running costs.
Service engineers with expertise in industrial applications understand the parameters that impact on electrical performance and can balance these with the need for maximum energy efficiency.
What About Knowledge of Industry Standards?
Industrial cooling systems must adhere to stringent industry standards and regulations.
A good example is in the food and beverage manufacturing and the defined ‘Hygiene Zone’ in which the equipment lies. Hygiene Zones are defined by the EN 1672-2:2005 Standard which determines the level of exposure the raw ingredients have to the environment and possible contaminants.
It is important to ensure that both Hygienic Design (HD) enclosures and HD climate control equipment is used within these areas. This equipment is designed specifically to ensure both that they can withstand the rigorous cleaning and high-pressure jets, and that there are no nooks and crannies which can harbour germs and cause a bacterial build-up.
Service engineers are familiar with these requirements and can ensure that all maintenance and servicing activities are legally compliant, and ensure the safety and reliability of the cooling units.
How Can Specialist Service Engineers Minimise Downtime & Costs?
Regular maintenance by specialised service engineers can significantly reduce the risk of unexpected breakdowns and downtime.
Breakdowns tend to spike during the summer months as ambient temperatures within a facility rise, particularly now that climate change has altered our weather patterns and we are seeing record rises in daytime temperature levels.
Service engineers use diagnostic software to understand the effect of this on the cooling unit and spot any potential issues before any problems arise. They can then recommend preventive measures to keep cooling units operational.
This proactive approach not only minimises hugely expensive production downtime, but it also reduces the long-term costs associated with repairs and replacements.
Tailored Solutions & Innovations
Service engineers in the industrial sector are typically very familiar with the latest hi-tech advancements and cooling innovations.
They can identify and specify tailored solutions based on the latest technologies to enhance the performance and reliability of cooling units within a particular manufacturing environment.
They can offer advice on upgrades, for example, if:
- There have been legislative changes and equipment is no longer compliant
- More efficient units have recently come onto the market
- Spares are hard to get or no longer available
- Recent investments in electrical systems mean that the original cooling specification is no longer high enough for the operational pressures placed upon it.
This forward-thinking approach ensures that factory teams can benefit from leading-edge solutions.
What is Meant by Preventative Maintenance of Cooling Systems Between Servicing?
There are also some simple maintenance checks that can be carried out by HVAC engineers or the facility’s own maintenance teams between servicing appointments, that can help support the efficient running of the cooling system.
These checks include:
- Regular checks for damaged seals, clogged filters, or unusual noises.
- Cleaning and replacing air filters as needed to maintain airflow and prevent contaminants from entering the enclosure.
- Periodically testing temperature controls to ensure they are functioning correctly and maintaining the desired setpoint.
- Monitoring systems that keep track of the temperature and performance of your cooling units and can provide early warning signs of potential issues.
RiAssure for Peace of Mind
A RiAssure FREE Cooling Review from Rittal means a local climate control expert will perform a short appraisal of your existing equipment, and give you honest feedback as to whether the equipment is adequate as well as any need for further maintenance.
Climate control equipment is becoming increasingly efficient with new cutting-edge technology coming on-line every year. The only guarantee of the highest level of checks and service will come from engineers who have been trained by the manufacturers about the technology and its detailed workings.
Rittal has been manufacturing industry-leading climate control equipment for 30 years and all of our service staff are highly trained on the whole portfolio to ensure they can remedy your issues.
