Overview
When a lighting strike disabled the twin cooling towers at a high-volume distribution center, compressor pressure began to climb and the refrigeration section, along with its perishable inventory, approached critical risk.
Within hours, our team was on-site, launching diagnostics and stabilizing operations.
Results At A Glance
The Challenge
The strike knocked out multiple fan motors, VFDs, and one tower controller. Proprietary components and limited OEM support complicated troubleshooting efforts, and with refrigeration offline, the facility needed a rapid, coordinated recovery plan to prevent spoilage and resume outbound operations.
The Solution
Fidus technicians arrived on-site within 5 hours of the initial call and immediately began assessing the cooling tower systems. The root issue was quickly identified: the towers had shut down due to rising compressor output pressure caused by inactive fan assemblies.
After completing a full electrical diagnostic - including wiring verification and component testing - the team narrowed the issue to three critical areas: a failed VFD, a non-operational motor, and a potentially compromised PLC controller. Rather than risk partial functionality, the team recommended a full replacement of all three components to ensure long-term system reliability.
Replacement parts were sourced from another facility within the retailer's network and coordinated for overnight delivery to minimize downtime.
Implementation
While parts were in transit, the Fidus team began preparing the site for reassembly. Damaged components were removed from the top of the towers, and all replacement equipment was pre-tested for continuity and integrity prior to installation.
Tower 2, whose controller remained functional, was prioritized and brought back online first. Once tower 1's controller arrived, the remaining motor and drive assemblies were installed, and full system functionality was restored. Both towers were fully operational within 72 hours of the initial failure.
The facility avoided product loss and a full refrigeration shutdown. Operations resumed without long-term disruption, and the site's cooling infrastructure returned to stable, reliable performance.
Conclusion:
In the face of an unexpected system-wide failure, Fidus Global delivered rapid response, strategic diagnostics, and efficient execution, all within a 72-hour window. Our technicians were on-site within hours, quickly aligned with facility teams, and coordinated a full-system recovery before critical thresholds were breached.
This level of responsiveness and reliability is what sets Fidus' field services team apart. When failure isn't an option, our teams go above and beyond to be the dependable partner operators can count on.