Common Fault Troubleshooting and Emergency Handling of Plastic Distribution Box Junction Boxes, ZCEBOX Helps You Solve Problems Quickly

1. High-Frequency Fault 1: "Poor Contact/Heating" Caused by Loose Wiring

Symptom Performance

• The wire connector inside the box heats up, and there is an obvious temperature rise when touching the outside of the box;

• The connected electrical equipment (such as lamps, motors) has frequent start-stop and unstable power phenomena;

• In severe cases, a burnt smell may be smelled, and even oxidation and blackening at the connector may be seen.

Troubleshooting and Emergency Handling

1. Safety Premise: First disconnect the upper-level power supply, and use a test pen to confirm that there is no residual voltage in the box;

2. Fault Location: Open the ZCEBOX junction box cover (the quick-release design requires no tools and can be opened in 10 seconds), observe whether the wire connectors have loose or oxidized traces, and focus on checking the crimping position of the wire ferrules of multi-strand wires;

3. Emergency Handling: Re-crimp the loose wire ferrules with a crimping pliers, replace the wires or connectors with severe oxidation, and then use a torque screwdriver to tighten the terminal blocks according to the torque marked in the ZCEBOX product manual (usually 1.2-1.8N·m) to avoid being too loose or too tight;

4. Prevention Suggestion: Use an infrared thermometer to detect the temperature of the connector every 3 months in industrial scenarios and every 6 months in civil scenarios. If the temperature exceeds 60℃, it needs to be handled in time.

2. High-Frequency Fault 2: "Insulation Deterioration/Short Circuit" Caused by Water Ingress in the Box

Symptom Performance

• When testing with an insulation resistance meter, the insulation resistance value is lower than 0.5MΩ (normally ≥1MΩ);

• The circuit breaker trips frequently and cannot be closed normally;

• There is obvious water accumulation or water droplets at the bottom or corner of the box, and the wire insulation layer is softened.

Troubleshooting and Emergency Handling

1. Safety Premise: Cut off the power immediately, and it is strictly forbidden to open the cover when energized;

2. Fault Location: Check whether the ZCEBOX box sealing rubber strip is aged and cracked, whether the cover plate screws are loose. For outdoor installation, focus on checking whether the rain eaves are damaged and whether the drainage holes are blocked;

3. Emergency Handling: Absorb the accumulated water in the box with a dry rag, and use a hair dryer (adjusted to low temperature) to dry the insulation layer and terminals (temperature not exceeding 60℃ to avoid damaging the material); replace the aged sealing rubber strip, tighten the cover plate screws, and clean the debris in the drainage holes; re-test the insulation resistance after drying, and power on only after it meets the standard;

4. Prevention Suggestion: Use ZCEBOX products of IP65 and above for outdoor use, check the status of the sealing rubber strip every quarter, and clean the drainage holes before the rainy season.

3. High-Frequency Fault 3: "Box Cracking/Structural Failure" Caused by Material Aging

Symptom Performance

• The box has obvious cracks, especially at the corners and screw fixing points;

• The cover plate cannot be closed tightly, and the sealing performance decreases;

• The surface of the box used outdoors for a long time is chalking and discolored, and the strength decreases.

Troubleshooting and Emergency Handling

1. Safety Premise: Disconnect the power supply to avoid wire exposure due to crack expansion;

2. Fault Location: Confirm whether the crack position affects the internal wires and terminals, and check whether the box load-bearing structure is intact;

3. Emergency Handling: If the crack is small and does not damage the internal components, special plastic repair agent can be used to seal the crack; if the crack is severe or the structure fails, the ZCEBOX product of the same model must be replaced immediately (the modular design can be directly replaced without re-wiring, saving 80% of the replacement time);

4. Prevention Suggestion: Choose products of corresponding materials according to the environment (such as UV-resistant modified materials for outdoor use), and avoid installing junction boxes in high-temperature and strong corrosion areas.

E-mail: sales@zcebox.com