Energy management and automation specialists Schneider Electric has unveiled its PowerLogic HeatTag, described as a smart sensor for early detection of overheating of wire connections or cables that analyses switchboard gas and particles and provides alerts before smoke or insulator browning can occur.

The sensor forms part of Schneider Electric’s Continuous Thermal Monitoring’ solutions, designed to reduce the risk of electrical fires and unplanned electrical downtime by measuring temperature at critical connection points in medium voltage (MV) and low voltage (LV) electrical equipment and off gassing of electrical wiring.

“Our PowerLogic HeatTag sensors offer a high level of sensitivity which means it can detect early signs of insulation deterioration through the analyses of gas and particles.  In turn, related data and alarms can be visualised locally by onsite facility personnel and uploaded to the cloud where remote facility personnel and expert advisory services can conduct the relevant maintenance and repair before damage occurs,” explains Schneider Electric AAF offer manager - PPACB & PPCCB Power Products division Kamogelo Makwana.

Cable connections can start to deteriorate as a result of improper tightening torque or constant vibrations over time. Deterioration can also occur owing to damaged surfaces because of corrosion, excessive pressure or friction.

These conditions can also be exacerbated by frequent temperature cycling. Fluctuations between cold nights and hot days, or low and high current, may cause increased and decreased connection tightness, which may contribute to loosening.

Increasing electrical contact resistance can induce a rise in temperature that accelerates damage, resulting in a thermal runaway that leads to overheating wire connections and/or overheating cables.

Above 200 °C, the insulation material begins to change colour. At approximately 300 °C this transforms into cable smoke, melted insulation material or even fire. These conditions can be detected with a fire or smoke detector, however, damage is likely to have already occurred in the electrical switchboard.

Schneider Electric’s PowerLogic HeatTags’ analysis of gas and particles is designed to provide early warning alarms to operators, ensuring that faulty cabling is replaced before permanent damage occurs.