How Zeller Technologies Protected a Critical New Electrical Installation from Premature Failure
Why Infrared Thermography Is Crucial in New Construction.
Electrical reliability isn’t just a maintenance concern—it starts at day one. That’s why Zeller Technologies integrates infrared thermography into new electrical construction projects. This proactive approach recently proved vital during commissioning of a newly installed MCC 3 Main Telemecanique panel at a secondary motor control center.
The thermographic inspection revealed a dangerous thermal anomaly on a critical bus connection—before any visible symptoms or equipment failure had occurred.
The Problem: Unexpected Heat Spike in New Panel
During a standard post-installation thermographic scan—performed with a FLIR T460 by our Level II certified thermographer—a thermal anomaly was detected in the MCC 3 Main Telemecanique unit. The infrared camera captured a significant heat rise of 167°F above reference temperature, localized at the C-phase bus connection of the main disconnect breaker.
Root Causes Considered:
- Improper torque on bus connections
- Internal corrosion of contacts
- Component aging (despite new install—possible manufacturing flaw)
This issue was invisible to the naked eye and presented no operational warning at the time. Left unchecked, it could have caused catastrophic failure or even electrical fire once the panel came under full load.
The Solution: Early Diagnostics, Immediate Correction
Zeller’s team took decisive action:
- Flagged the anomaly for immediate corrective maintenance
- Recommended tightening, cleaning, or replacement of the affected C-phase terminal
- Suggested a follow-up thermographic scan post-correction to confirm temperature normalization
This intervention occurred prior to full energization, preventing future downtime or equipment damage and reinforcing safety compliance.
“Thermography helped us catch a critical issue before it became a crisis. Zeller’s team made sure our system was reliable from the start.”— Site Maintenance Lead
The Result: Failure Prevented, Standard Set
Thanks to Zeller’s predictive inspection protocol, a major fault was prevented before the facility reached production. The panel’s issue was:
- Identified and corrected early
- Logged for future trend analysis
- Validated through re-inspection
The thermographic analysis is now being incorporated as a standard commissioning step for all major electrical construction projects—setting a new reliability benchmark.
Why This Matters
This case exemplifies the value of pairing traditional electrical craftsmanship with modern diagnostic tools. Zeller Technologies’ legacy of reliability is strengthened by innovation—helping customers avoid unexpected costs, extend asset life, and meet safety standards from day one.
Learn More
Explore how Zeller’s Infrared Thermography Services can improve reliability across your plant.
✅ View our Preventive Maintenance Services
✅ Learn More about our Motor Services
✅ Contact Zeller for Thermographic Baseline Scans
Case Study Summary
- Client: Industrial facility (new construction)
- Equipment: MCC 3 Main – Telemecanique
- Service: Infrared thermographic inspection
- Issue Found: 167°F thermal anomaly on C-phase bus connection
- Action Taken: Immediate correction and re-scan scheduled
- Outcome: Hazard mitigated; standard procedure validated