Everyone, please help analyze the reasons for the TRICONEX controller burning out
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Here’s what happened: after the installation of the instruments for our project was completed, we carried out individual tests. During the lunch break, suddenly the Triconex controllers started failing one after another. Upon inspection, it was found that the varistors had blown, but the fuses had not blown, and the upstream circuit breakers had not tripped. We checked the UPS, and there were no alarms. I asked the people from the UPS manufacturer what the alarm threshold for the UPS output was, but they couldn’t tell me; it turns out that such a record doesn’t exist. After the incident occurred, we checked the UPS and the wiring, and no abnormalities were found. Now we’re too afraid to turn the power on again. Fellow netizens, has anyone encountered such an issue? Could you provide some answers? We’re also trying to find the solution.
I think there are two reasons: 1. There is a problem with the product itself. 2. The voltage output by the UPS is overvoltage.
There should be two power supply sources. Does your UPS have an inverter or voltage stabilizer? Even if not, this issue might still occur. The second source is the mains electricity; could the voltage there be too high momentarily?
This issue is quite strange; check the power supply or the lightning protection measures
I checked the radar level gauge today; it is also powered by 220VAC from the UPS, and I found that it had been damaged as well. It’s now clear that the issue lies in excessive voltage, though the cause has not yet been identified. I will continue to report on the progress of my investigation. Thank you
1. The design specifications of Conson (the company that develops TRICON) are problematic; I have worked on two projects with them, and even their chief engineers have a very basic understanding of power supply-related concepts, resulting in rather rough choices when it comes to component selection. I think it’s normal for such problems to occur. Back then, at my suggestion, that project had the ICS and TRICON systems completely reworked in terms of their power supply before power was supplied to them again. 2. The design institute is definitely trash too. Electrical design requires qualified personnel; not just anyone can handle power distribution design, and almost all design firms have never paid attention to this. 3. The supervisor is definitely trash too. Overall, there must have been problems in every stage. None of them are finished.
I’ve been trying to find the cause of this issue over the past two days. At first, I thought there was a problem with the UPS’s three phases; it’s possible that one of the phases was grounded, which caused the voltages of the other two phases to rise. After checking, it was found that all three phases were damaged. A test for uneven load conditions was conducted on the UPS, but no problems were detected. Today, someone from the electrical department of the design institute came to the site to deal with this issue; I’m waiting to hear back
Has the specific reason been found? I’ve solved it, so I’ll tell you all about it; also, please pay attention
Were there no other tests being conducted at the time of burning? If you use a megohmmeter to test grounding, for example, that involves high voltage
I’m sorry for keeping everyone waiting; I was on a business trip and couldn’t respond. The results are as follows: Surface conclusion: There was a short-circuit issue with other devices at the site. This was because the circuit breaker chosen was too large, and it had a C-shaped curve, so it didn’t trip and thus prevented electricity from flowing to the other two phases. Since the TRICONEX unit had low power capacity, it was the first to get damaged. The fundamental issue was that the neutral wire of the UPS three-phase power supply was floating; later, all the neutral wires, ground wires, and neutral wires were rewired. Remedial measures: All devices with a power rating of over one kilowatt should be re-evaluated; circuit breakers need to be replaced, as well as cables. This approach ensures that the system trips in a timely manner when problems arise, and it is something worth adopting. Thank you all for your attention; we hope that this incident of ours can be of help to you.