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Fan Failure Modules

Fan Failure Modules

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Heating Issues:

DCS-panel -with -cooling -fans

Pic. DCS panel with cooling fans


Complex -control -system

Pic. Complex control system increases number of components.


Control Panels are designed to house and protect electrical components for powering and controlling industrial, HVAC, and other equipment. Industrial control panels include PLCs, VFD drive’s, contactors, fuses, switches, transformers, timers, and other components that operate within an optimal temperature range.

If the temperature of a control panel rises above the specified temperature for one or more components; it decreases the efficiency of the equipment or ends up damaging the equipment. This results in increase in increased maintenance and replacement costs, loss of power and ultimately failure of the system.

80% of the devices used today rely heavily on semiconductors. The semiconductors get heated very quickly while functioning.  These components are used in every panel. The second biggest heat-generating component in the control panel is a transformer. There are different voltages for different countries and industries which makes transformers an essential component of the design. Application of Transformer is found in following devices:

1)   Power supplies
2)   Converters
3)   Electronic boards.


These devices generate heat while in operation. When the heat load of the electrical devices within an enclosure exceeds the heat dissipation achieved through natural convection; the temperature inside the enclosure rises. Since the performance and lifespan of electrical devices will degrade as temperature increases, this excessive heat must be eliminated to keep the temperature rise at bay.

Refer below image captured by the pyrometer of a DCS panel


Pic.: Heat emitted by the devices in control panel.

The above image indicates the temperature, blue stands for the minimum temperature and red for the maximum temperature.

The “rule of thumb” warns that for every 10°C over their rated temperature limit, the life expectancy for electrical components gets cut in half.

For example if we take a film capacitor which is used in all electronics circuits. e.g., PLC’s snubber circuits. Refer to the below curve to check how the temperature affects the life expectancy of the components.




Some natural cooling will occur when excess heat inside the control panel is transferred through the panel walls to the outside air or through convection currents as heated air rises and escapes from vents near the top of the enclosure.  Earlier conventional air cooling was used for cooling the control panel. However today the conventional air cooling does not serve the purpose as the heat generation rate has is higher than the cooling rate. Here forced cooling such as fan cooling and air conditioning (using refrigerators) options are used.

Cooling by air conditioning (refrigerators) is very expensive and cannot be used in every application as it requires more space and becomes bulky. This system is used where the ambient temperature is beyond the operating temperature of the components or where the heat generation rate is high.



Forced cooling using a fan is the most commonly followed method in the industry. However fans may fail in several ways and failure may be defined differently depending on the applications. Fan failures typically include excessive vibration, noise, rubbing or hitting of the propeller, reduction in rotational speed, locked rotor, failure to start, etc..

The Fan failure models can be programmed as per the fan used, failure can be sensed by overcurrent or less current consumption than the defined current. Overcurrent occurs when the mechanical movement of the fan is obstructed like bearing failure, obstruction due to particles etc. And less current is consumed if the motor of the fan is damaged.

By using the current measurement; a fan failure module not only detects the failure but also stops the supply to the fan and provides the relay alarm accordingly. So the user understands the exact failure location and the fault which can be attended to easily and immediately so that the other failures due to high temperature can be avoided.

These fan failure modules are equipped with temperature measurement which continuously measures the temperature. If the panel temperature exceeds the set temperature, it generates a relay alarm which can be attended to easily. It also provides a 4-20mA analogue signal to continuously monitor the temperature of the panel.



Fan failure module can be used in the following applications

1.      Where there is a possibility of increase in the temperature beyond
         the limit of the operating temperature of the components used.

2.      Solar panels.

3.      DCS system.

4.      Automation panels.

5.      HVAC panels.

6.      MCC panels.

7.      Every panel which includes components whose life
         decreases with increase in temperature.



1.     The efficiency of the system can be increased by
         monitoring the temperature.

2.     The cost of maintenance can be minimised.

3.     Minimises temperature-related failures and shut-downs
        which reduces costly downtimes.

4.     Extends the life of critical electronics.


Connectwell Fan Failure Modules:

We offer a complete range of fan failure modules

1.      IMFF/1





  • Compact and standard DIN Rail mounting.
  • Isolated fan monitoring unit.
  • Fan monitor for 2 fans.
  • Adjustable fan over current.
  • LED Indication for FAN OK, FAN FAIL, FUSE FAIL,
    and FAN TRIP SET.
  • Fuse protection to each module.


2.      IMFF/2




  •  Compact and standard DIN Rail mounting.
  •  Isolated fan monitoring unit.
  •  Fan monitor for 4 fans.
  •  Adjustable fan over current.
  •  LED Indication for FAN OK, FAN FAIL, FUSE FAIL,
     and FAN  TRIP SET.
  •  Fuse protection to each module.


3.      IMFFTD/2





  •  Compact and standard DIN Rail mounting.
  •  Isolated fan monitoring unit.
  •  Fan monitor for 2 fans.
  •  Adjustable fan over current.
  •  LED Indication for FAN OK, FAN FAIL, FUSE FAIL, and FAN TRIP SET.
  •  Fuse protection to each module.
  • 2 Digit temperature display
  •  Temperature set point operation
  •  4-20mA current output
  •  Temperature relay.