In the spring and summer season, there is more rain and the air humidity is relatively large. Dew drops and fog are generated when the air is wet, and when the heat is suddenly changed. This increases the conductivity of the air. In particular, the carton printing machinery factory, when working in the workshop, is very dusty and can easily cause the condensation of dust and condensation in the air. If dust adheres to electrical components, it will cause direct current leakage and short circuit, especially for high-precision electrical devices such as PLCs, servo drives, inverters, DC speed regulators, etc., which can easily lead to abnormal work or direct short-circuit burnout. Serious fire can also cause incalculable losses. Therefore, we must attach great importance to the breakdown and maintenance of mechanical equipment.
In wet weather, mechanically prone failures mainly include the following aspects:
Fault 1: Programmable controller (PLC) program is lost, or PLC's CPU is directly damaged. Because the dust has moisture, the conductivity becomes strong, and it adheres to the two levels of the battery and is in a state of semi-short-circuit leakage. When the battery leakage is lower than a certain voltage, the program stored in the PLC will be lost, causing the device to fail to operate.
Fault 2: The short circuit of the DC power supply module causes abnormal control voltage, which prevents the system from providing control power and the equipment cannot work.
Fault 3: The inverter trips and the DC governor is damaged.
Fault 4: The contacts of the contactor are short-circuited, the three-phase power supply is short-circuited, and the terminals short-circuit and ignite. The machine breaker trips, unable to power up the machine.
For example: Oriental TOPRA printing press used in a factory in Xiaoshan, Zhejiang, February 2011 feedback machine can not run, after inspection is the loss of PLC program. The reason is that during the holiday of the New Year, when the snow melts after snow, the weather is warm and humid, the PLC battery cover is not covered, and the inside is covered with dust, causing a short circuit, which causes the PLC battery power to leak. The machine was not charged for a week, so the program was lost.
In addition, the East TOPRA-MD1224 printing slot machine used by a factory in Dongguan, Guangdong Province, in April 2011, reflected that the equipment in use was automatically shut down after running for about ten minutes, and told me that the inverter tripped and asked the inverter again. The fault code is an over-temperature trip in the inverter. The reason is that in April, when it rains frequently, dust is attached to the inverter and causes a short circuit, causing the inverter's own relay output circuit of the cooling fan to be abnormal or in a protected state. The cooling fan does not work properly when the inverter is running. In this case, if you use the air gun to clean the dust of the inverter and then start the machine again, the cooling fan of the inverter can work normally, and the inverter will no longer trip and everything will return to normal.
The above faults are caused by wet weather and dust, so regular maintenance of the equipment during the wet season is very important. To turn sudden failures into predictable and planned outage repairs, identify potential hazards in a timely manner so that they can prevent them from occurring, and in particular, prevent short-circuit accidents caused by moisture.
Based on the above cases, how do we maintain the equipment in wet weather?
Method one: regularly remove dust that adheres to electrical equipment, especially carton plants, where both the size and the dust are, and dust is pervasive, especially small dust, easily absorbs moisture, and is more easily attached to electrical components. It is an invisible electrical component. "Killers," so it is recommended to use an air pipe every two days to clean dust on all electrical devices on the machine, such as PLCs, inverters, etc.
Method two: Tighten the screw of the contactor terminal and fasten the screw of the terminal to prevent short circuit due to poor contact.
Method 3: The dust cover of the electric device must be properly covered, such as the battery cover of the PLC. Inverter cover, etc., check whether the exhaust fan of the electric cabinet is in good condition. If it is damaged, replace it in time. The electrical cabinet door should be closed, and check that the gasket is intact and minimize the dust entering the electrical cabinet. At the same time, desiccants can also be placed in the electric cabinet to reduce the humidity of the air, and the desiccant is often replaced.
Method 4: Maintain at least 40 minutes to 60 minutes of the machine's warming-up operation every day, let the machine warm up to produce temperature and dry the electronic components. There is also a purpose to charge the PLC's CPU battery. For machines that use the longer time, The more important it is to start warming up.
Method 5: Install a dehumidifier in the workshop. Reduce humidity and prevent condensation from adhering to electrical components.
Method 6: Pay attention to anti-rust, apply some oil on the rust-prone parts of the machine to prevent rust.
As long as we carefully do the above points, the failure rate will gradually decrease. At the same time, it also indirectly reduces costs and improves the utilization of machinery and equipment, thereby increasing the efficiency of each company that uses equipment.
In wet weather, mechanically prone failures mainly include the following aspects:
Fault 1: Programmable controller (PLC) program is lost, or PLC's CPU is directly damaged. Because the dust has moisture, the conductivity becomes strong, and it adheres to the two levels of the battery and is in a state of semi-short-circuit leakage. When the battery leakage is lower than a certain voltage, the program stored in the PLC will be lost, causing the device to fail to operate.
Fault 2: The short circuit of the DC power supply module causes abnormal control voltage, which prevents the system from providing control power and the equipment cannot work.
Fault 3: The inverter trips and the DC governor is damaged.
Fault 4: The contacts of the contactor are short-circuited, the three-phase power supply is short-circuited, and the terminals short-circuit and ignite. The machine breaker trips, unable to power up the machine.
For example: Oriental TOPRA printing press used in a factory in Xiaoshan, Zhejiang, February 2011 feedback machine can not run, after inspection is the loss of PLC program. The reason is that during the holiday of the New Year, when the snow melts after snow, the weather is warm and humid, the PLC battery cover is not covered, and the inside is covered with dust, causing a short circuit, which causes the PLC battery power to leak. The machine was not charged for a week, so the program was lost.
In addition, the East TOPRA-MD1224 printing slot machine used by a factory in Dongguan, Guangdong Province, in April 2011, reflected that the equipment in use was automatically shut down after running for about ten minutes, and told me that the inverter tripped and asked the inverter again. The fault code is an over-temperature trip in the inverter. The reason is that in April, when it rains frequently, dust is attached to the inverter and causes a short circuit, causing the inverter's own relay output circuit of the cooling fan to be abnormal or in a protected state. The cooling fan does not work properly when the inverter is running. In this case, if you use the air gun to clean the dust of the inverter and then start the machine again, the cooling fan of the inverter can work normally, and the inverter will no longer trip and everything will return to normal.
The above faults are caused by wet weather and dust, so regular maintenance of the equipment during the wet season is very important. To turn sudden failures into predictable and planned outage repairs, identify potential hazards in a timely manner so that they can prevent them from occurring, and in particular, prevent short-circuit accidents caused by moisture.
Based on the above cases, how do we maintain the equipment in wet weather?
Method one: regularly remove dust that adheres to electrical equipment, especially carton plants, where both the size and the dust are, and dust is pervasive, especially small dust, easily absorbs moisture, and is more easily attached to electrical components. It is an invisible electrical component. "Killers," so it is recommended to use an air pipe every two days to clean dust on all electrical devices on the machine, such as PLCs, inverters, etc.
Method two: Tighten the screw of the contactor terminal and fasten the screw of the terminal to prevent short circuit due to poor contact.
Method 3: The dust cover of the electric device must be properly covered, such as the battery cover of the PLC. Inverter cover, etc., check whether the exhaust fan of the electric cabinet is in good condition. If it is damaged, replace it in time. The electrical cabinet door should be closed, and check that the gasket is intact and minimize the dust entering the electrical cabinet. At the same time, desiccants can also be placed in the electric cabinet to reduce the humidity of the air, and the desiccant is often replaced.
Method 4: Maintain at least 40 minutes to 60 minutes of the machine's warming-up operation every day, let the machine warm up to produce temperature and dry the electronic components. There is also a purpose to charge the PLC's CPU battery. For machines that use the longer time, The more important it is to start warming up.
Method 5: Install a dehumidifier in the workshop. Reduce humidity and prevent condensation from adhering to electrical components.
Method 6: Pay attention to anti-rust, apply some oil on the rust-prone parts of the machine to prevent rust.
As long as we carefully do the above points, the failure rate will gradually decrease. At the same time, it also indirectly reduces costs and improves the utilization of machinery and equipment, thereby increasing the efficiency of each company that uses equipment.
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