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Temperature Controller Common Troubleshooting and Problems

09th Sep 2024

Temperature controllers are essential to maintain the desired temperature in various systems like industrial machineries, HVAC systems, and home appliances. But like any other equipment, they can occasionally face issues. Let’s go over common problems with temperature controllers, troubleshooting tips, and how Tosunlux’s temperature controllers can help you avoid these issues. 5 Common Problems with Temperature Controllers What are the common problems people encounter with temperature controllers? The common problems with temperature controllers are: Inaccurate temperature readings; Controller not responding to setpoint changes; Overshooting or undershooting the setpoint; Temperature fluctuations; and Faulty output Inaccurate Temperature Readings One of the most common problems is inaccurate temperature readings. This can be due to a faulty sensor, poor sensor placement, or incorrect calibration. Solution: Check the sensor for damage and ensure it’s properly placed. Recalibrate the controller according to the manufacturer’s guidelines. Controller Not Responding to Setpoint Changes Sometimes, the temperature controller may not respond to adjustments in the setpoint. This can be due to a malfunction in the control panel or wiring issues. Solution: Inspect the wiring connections and control panel for any loose or damaged parts. Reset the controller if necessary and verify that the setpoint is within an acceptable range. Overshooting or Undershooting the Setpoint Another common issue is when the temperature controller overshoots or undershoots the setpoint. This typically occurs in older models or when the PID parameters are not correctly set. Solution: Reconfigure the PID settings to fine-tune the control system. If the issue persists, consider upgrading to a more modern and responsive […]
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What Is the Difference Between AC MCB And DC MCB?

08th Sep 2024

Miniature Circuit Breakers (MCBs) are crucial for safety in electrical systems. They prevent overloads by interrupting the circuit when necessary. However, there are important distinctions between AC MCBs and DC MCBs. In this guide, we’ll explore their unique features, uses, and key differences to help you choose the right MCB for your needs. Key Differences Between AC MCB and DC MCB The following table highlights the main differences between AC and DC MCBs based on structure, applications, and technical specifications: Feature AC MCB DC MCB Current Type Alternating Current (AC) Direct Current (DC) Arc Suppression Handles arc interruption more easily Requires larger arc suppression mechanism Applications Used in homes, offices, and AC circuits Suitable for solar, battery, and DC circuits Breaking Capacity Lower, due to easier arc suppression in AC Higher, to manage steady DC current Polarity Sensitivity Not polarity sensitive Polarity sensitive Lifespan Longer in AC due to arc dissipation Shorter as DC arcs wear components faster Design and Functional Differences Between AC and DC MCBs Arc Suppression In AC systems, the current naturally crosses zero, making it easier to control the arc formed when a circuit is interrupted. An AC MCB is designed with this zero-crossing in mind, so arc suppression is less demanding. In contrast, DC MCBs need larger arc chutes or magnets to handle steady DC current since it flows in only one direction. These components dissipate heat and extinguish the arc, ensuring safe interruption. Polarity Sensitivity AC MCBs are not polarity-sensitive and can be installed without worrying about directional currents. […]
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How Do I Choose a Temperature Controller?

08th Sep 2024

Choosing the right temperature controller is essential for ensuring accurate and reliable temperature management, be it for home, commercial, or industrial uses.. But that can be difficult to do if you’re not a technical person. This guide will help you understand what things to consider when selecting temperature controllers. What Are Temperature Controllers? What are temperature controllers? Temperature controllers are devices designed to maintain a specific temperature within a given system. It does this by monitoring and adjusting the heating or cooling processes. They are widely used in industries like manufacturing, food processing, HVAC, and even home appliances. These controllers ensure that the equipment or environment operates within the desired temperature range, enhancing safety, efficiency, and quality. There are various types of temperature controllers, including on/off, proportional, and PID controllers, each suited to different needs. Tosunlux offers a range of digital temp controllers that provide precise and reliable solutions for a wide range of applications. Related Reading: Temperature Controller Complete Guide 7 Factors to Consider When Choosing Temperature Controllers When selecting the right temperature controller, several factors need to be considered to ensure optimal performance. Below are the key elements to focus on: 1. Application Requirements The first step in choosing a temperature controller is understanding your application. Is the controller needed for industrial equipment, a household appliance, or a laboratory setting? The type of environment in which the temperature controller will be used determines the specific features and capabilities you’ll need. Expert Tip: For heavy-duty environments, consider a controller with advanced protection features […]
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Which Is Better Terminal Box Or Junction Box

28th Aug 2024

Electrical junction box is this small metal or plastic box which enclosure housing electrical connection. It is a part of an electrical conduit wiring system in a building that shields the electric connection from weather and accidental electric shocks. It is designed in-ceiling floors or concealed behind a panel particularly in commercial or domestic buildings. Sometimes they are embedded in plaster walls so that only the cover is visible from outside. junction box is also included in building terminals for the joining of wires. A wall-mounted box is used to support switches sockets and connecting wires. These types of junction boxes are mainly used in large items such as a piece of street furniture. In a country like the UK, this junction box has mainly been termed a cabinet. Junction boxes are the main part of the protection of the circuit system where circuit integrity has to be granted for emergency or power lines or the wiring between a nuclear reactor or a control room. In such a situation, to cover the junction box fireproofing is necessary as incoming or outgoing cables to prevent unexpected fire or a short circuit inside the box. How junction box work? The junction box work as a mutual meeting spot for electric wires that connect before moving onto the main circuit. These box guards are hot, neutral, grounding copper wire and some other secondary functioning lightning electric wires. All junction boxes are covered, installed correctly, and in compliance with the applicable building quotes. They cover and protect the wire […]
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Everything You Need to Know About Busbars

19th Aug 2024

Busbars play a vital yet oft overlooked role in electrical power systems, providing the framework for current to safely and efficiently flow. As facilities look to push their systems to higher capacities with optimized designs, properly specifying busbars proves increasingly important. Their conductivity, flexibility, and protective functions make busbars the true workhorses transmitting lifeblood to electrical rooms. Busbars efficiently distribute high currents with minimal resistance and losses Configurable designs accommodate changing layouts and component additions Protective elements safeguard equipment from faults while enhancing uptime Dissipating heat loads protects connections from overheating Let’s find out everything one should know about busbars: What is a Busbar? What is a busbar used for? Constructed from highly conductive materials like copper and aluminum, busbars form the direct metallic pathways carrying heavy loads throughout facilities. By offering low impedance compared to cable runs, they allow power to smoothly flow from external feeds and busway entrances to individual circuit breakers and switchgear loads. Copper Busbars effectively minimize voltage drop and maximize load serving capacity. Conduction and Distribution Networked in parallel at their connection points, busbars simultaneously feed multiple downstream devices while balancing loads. Uniform current distribution prevents overburdening any single cable or component. Their grid-like topologies further allow flexible rearrangement and future proofing of layout changes with minimal rework. Connection Flexibility Busbar systems spare integrators the hassle of running countless individual conductor runs by providing pre-manufactured “plug and play” modular architectures. Strategically placed bolted or clamped joints enable rapid installation and reconfiguration of outgoing circuit configurations with ease. Design Configurations Common […]
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Everything You Need to Know About MPPT Solar Charge Controllers

19th Aug 2024

When implementing photovoltaic systems, selecting an optimal solar charge controller is imperative for maximizing energy yields from solar panels. As operations look to extract every potential watt-hour from their renewable assets, MPPT charge controllers have emerged as the foremost solution for off-grid and battery-based PV applications. MPPT technology allows up to 30% more energy production over PWM controllers Match controller ratings to system voltage and current capacity for top performance Advanced monitoring and customizable features facilitate system oversight Proper sizing ensures a flexible platform supporting evolving energy needs By continuously tracking the true maximum power point of solar modules, these controllers optimize electrical harvesting regardless of changing field conditions. What is MPPT Solar Charge Controller? At its core, MPPT stands for Maximum Power Point Tracking. By intelligently monitoring module performance metrics, MPPT controllers locate and maintain operation at the precise voltage where solar panels generate their highest wattage output. This optimal power point naturally drifts with irradiance levels and temperature fluctuations, so algorithms dynamically adapt voltage conversion to stay locked on. How MPPT Works Converters within the MPPT solar regulator function as the linking node between solar arrays and battery banks or loads. Independent of downstream system voltage, these step-up or step-down boosters transform incoming DC to suit the battery while continuously tracking fluctuations in the solar maximum. Regardless of environmental shifts, the controller adjusts the operating point to pump maximum current into storage. Applications of MPPT Solar Charge Controllers Off-grid solar installations especially stand to gain from MPPT performance advantages. Remote community microgrids, telecom […]
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How to Choose a DC Circuit Breaker?

19th Aug 2024

No matter which DC powered system you are outfitting, properly selecting and installing circuit breakers is crucial for safety and long-term reliability. But with so many breaker types, sizes, and tricks to the trade, how do you make the right choice? Let’s break down the key factors. Key Considerations There are a few major things to evaluate when choosing DC breakers: Voltage Rating DC breakers are rated for specific voltage ranges, so this must exactly match your system voltage. 12V automotive circuits use 12V or 12-32V breakers. Marine tinned copper wire needs higher 32V or 50V ratings. Overvolting a circuit breaker for DC voltage risks failure or fire. Always stay within the voltage window marked on the breaker. Current Rating This reflects the maximum continuous load the breaker can safely handle indefinitely. It’s listed as amps (A) and must exceed the total draw of everything downstream on that circuit. Include start-up surge loads from motors too. Unsure of the draw? Rate for 125% of wire capacity as a safety factor. Interrupting Capacity Shown as “iC” or “IC”, this is the breaker’s short-circuit withstanding limit in kA (thousands of amps). Higher iC handles severe power surges safely without welding contacts. Use iC matching or exceeding the circuit’s maximum short-circuit current if possible. This protects wiring in failure modes. Breaker Quality Cheap breakers can fail to trip under load or arc weld shut. Stick with top brand names like Blue Sea Systems, Reliance or Westmarine for durability. Consider ones with sealed covers and vibration resistance for marine […]
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Is a Copper Busbar Better Than Aluminum?

17th Aug 2024

When assembling electrical control panels, switchgear, and industrial power distribution systems, the busbar is a critical backbone carrying large currents within tight tolerances. For this core application, spec’ing the right busbar material matters greatly. Copper has long been the industry standard, but is aluminum gaining ground as a lower-cost alternative? Aluminum Busbar vs Copper Busbar – Key Differences Let’s examine the pros and cons of different types of busbars. Electrical Conductivity On a fundamental level, copper has an edge due to its higher conductivity compared to aluminum. As current density rises in busbars, resistance heating becomes more problematic – and copper generates less waste energy through I2R losses. For applications involving frequent overload conditions or variable load profiles, copper’s superior heat dissipation maintains cooler operating temperatures that prolong component life. However, enhanced aluminum alloys have narrowed the gap, bringing conductivity about halfway between aluminum and copper. Mechanical Durability Copper also endures mechanical stresses like vibration and thermal cycling better than softer aluminum over the long haul. Its work-hardening characteristics generate a protective oxide patina providing self-healing corrosion resistance indoors. But modern alloys give aluminum overlapping outdoor durability when properly treated and welded. Material Cost Analysis While copper outperforms electrically and mechanically, aluminum has a compelling attribute – cost. On a pound-for-pound basis, high-purity aluminum sells for approximately one-third less than copper. Considering multi-ton bus systems, savings stack up fast when downsizing materials. However, a true value assessment should factor for total cost of ownership over the years. Copper’s reliability may allow longer service periods before […]
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The Global Top 10 Junction Box Manufacturers

16th Aug 2024

Junction boxes, a type of electrical box, serve a crucial insulation and protection function wherever electrical circuits merge and split, making them an essential infrastructure element across industries worldwide. As electrification proliferates into new sectors, established junction box powerhouses continue expanding their offerings to remain at the forefront. Hero Product Highlight TJB1 Waterproof Plastic Junction Box The TJB1 Waterproof Plastic Junction Box is designed for secure and durable connections, providing effective protection against environmental elements in both residential and industrial settings. View Product Junction Box Manufacturers – Top 10 Picks for Junction Boxes Rank Manufacturer Key Features 1 TOSUNLux High-quality junction boxes, extensive catalog, worldwide certifications, and customer service. 2 CZ Electric Co., Ltd Certified electrical products, exports to over 50 nations, and strong quality controls. 3 KAISER Group IP-rated fiberglass, aluminum, and steel boxes; fireproof models; technical consultations. 4 Hammond Manufacturing NEMA and UL certified plastic and metal boxes; customized panel options; built-in clamps for secure cable management. 5 Marechal Electric Ex certified enclosures, compliance with global directives, and connection technology innovation. 6 Takachi Die-cast aluminum, stainless steel, and plastics enclosures; bespoke services. 7 HuanYe Electronics IEC, EN, and UL standard boxes; value-added logistics services. 8 Polycase Military-spec tested products; custom engineering capabilities. 9 Turck, Inc Proprietary sensors, interface technology, and fieldbus networking; multilingual support. 10 Power Wholesale Certified mild steel or stainless boxes; rapid fulfillment abilities. 11 Schneider Electric Global leader in energy management and automation; diverse range of junction boxes, including fan-rated boxes for ceiling fans. 12 ABB Ltd. Comprehensive electrical solutions; […]
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The Top 5 Busbar Manufacturers in China in 2024

16th Aug 2024

As essential components transmitting heavy electrical currents, busbars play a vital role in industries and infrastructure. Here are the leading Chinese companies producing these conductive infrastructure elements at massive scales through advanced automated facilities and stringent quality protocols. Hero Product Highlight Busbar Support The Busbar Support is designed to securely support and stabilize busbars in electrical systems, ensuring durability and optimal performance in industrial applications. View Product China Busbar Manufacturers – Top 5 Picks Here are 5 of the well-known busbar manufacturers available in China: TOSUNLux Founded in 1994, TOSUNLux established expertise crafting low-voltage switchgear and busduct systems. Certified production lines roll out millions of aluminum and copper bars tailored for utilities, manufacturing plants, and more. Value-added services like anti-corrosion treatments and bolt-hole machining simplify installations. A global network provides localization support to major construction projects. Clients appreciate the company’s durability and rapid response to custom modifications. Yueqing Gaoke Environmental Electric Co., Ltd. Established in Yueqing in 2007, Gaoke now contributes over 10% of China’s busbar output via continuous optimizations. ISO certified workshops fabricate bars from electrolytic tough pitch (ETP) copper for maximal conductivity. Options include pre-drilled cross-sections, pre-assembled joints, and integrated flexible jumpers minimizing integration work. Their eco-friendly credentials attracted high-profile solar and hydro plants demanding low inductive impedance. Hero Product Highlight Comb Busbar The Comb Busbar is designed for efficient and safe electrical distribution, ensuring secure connections and optimized performance in high-demand environments. View Product Wenzhou Yopu Electric Co., Ltd. Founded in 2005 in Zhejiang, Yopu established expertise innovating busbar solutions. Continuous testing […]
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Blog

Temperature Controller Common Troubleshooting and Problems

09th Sep 2024

What Is the Difference Between AC MCB And DC MCB?

08th Sep 2024

How Do I Choose a Temperature Controller?

08th Sep 2024

Which Is Better Terminal Box Or Junction Box

28th Aug 2024

Everything You Need to Know About Busbars

19th Aug 2024

Everything You Need to Know About MPPT Solar Charge Controllers

19th Aug 2024

How to Choose a DC Circuit Breaker?

19th Aug 2024

Is a Copper Busbar Better Than Aluminum?

17th Aug 2024

The Global Top 10 Junction Box Manufacturers

16th Aug 2024

The Top 5 Busbar Manufacturers in China in 2024

16th Aug 2024