Except for the VOC machine system
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Except for the VOC machine system
Description
Preface
To ensure the stability and durability of the equipment, this process document has been specially prepared. During production and use, please be sure to strictly follow the procedures outlined in this document for equipment maintenance and cleaning. If equipment damage occurs due to failure to adhere to the specified processes during maintenance and cleaning, our company shall assume no responsibility!
Warning!
Control system parameters directly affect the performance of the entire machine; unauthorized personnel are not permitted to modify these parameters.
Maintenance and cleaning personnel must be operated by trained and qualified individuals.
The control cabinet is energized and must be operated only by qualified electricians.
The emergency stop switch is used for immediate shutdowns; during maintenance or cleaning, it’s essential to turn off the main power supply and close the main air line valve.
To prevent electric shock, it is strictly prohibited to modify or dismantle the power regulator yourself—otherwise, there is a risk of electrocution.
Non-electrical construction professionals should not perform maintenance, inspections, or component replacements, as this could result in the risk of electric shock.
Installation, wiring, repair, inspection, and component replacement must be performed by qualified professionals.
Please do not remove the power regulator's cover or touch the printed circuit board while the unit is powered on, as this may result in electric shock.
To prevent fire hazards, before powering on, please ensure that the device's rated voltage matches the actual power supply voltage—and verify that any voltage fluctuations remain within ±5%.
Equipment Inspection and Maintenance Plan
| Inspection and Maintenance Items |
Class-by-Class Plan 8 hours |
Weekly Plan 50 hours |
Monthly Plan 250 hours |
Six-month plan: 1,500 hours |
| Comprehensive inspection of the equipment's overall appearance |
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| Such as equipment deformation, leakage, obstructions... |
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| Check the safety devices installed on the equipment. |
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| Such as protective isolation shields, grids, safety switches... |
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| Inspect the inside condition of the tank |
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| Leftover materials, adhering residues, friction marks... |
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| Check the power supply |
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| Voltage, three-phase power supply, electrical control box... |
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| Check the compressed air used by the equipment |
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| Air pressure, air leakage, compressor power-on... |
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| Inspect material transfer pipelines and accessories |
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| Are the material transfer pipelines, such as suction pipes and glass bent tubes, installed correctly and free from damage... |
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| Check the gas and material shut-off valve |
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| Check whether the cylinder action is damaged or leaking, and ensure the rubber stopper seals tightly... |
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| Check the suction bucket |
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| Is the lid of the suction hopper securely closed, and can the discharge tongue be tightly shut—without any damage? |
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| Inspect the negative-pressure pipeline and accessories |
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| Are the negative-pressure pipes and fittings installed correctly, and are there any air leaks or damages? |
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| Check the suction machine's fan |
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| Is the suction machine's fan operating with normal sound and vibration...? |
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| Check the suction machine filter element |
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| Is the suction machine filter clogged...? |
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| Check the level gauge |
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| If any abnormalities are found, replace them promptly. |
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| Check the weighing module (if applicable) |
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| Check whether the weighing module's weight exceeds the tolerance. |
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| Check the thermocouple |
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| If any abnormalities are found, replace them promptly. |
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| Check the electric heating tube |
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| If any abnormalities are found, replace them promptly. |
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| Check the heating curve during equipment operation |
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| If any abnormalities occur, promptly adjust the setting parameters and inspect the heating module. |
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| Check the material transfer speed during equipment operation |
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| If any abnormalities occur, promptly adjust the setting parameters. |
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| Check the operating status of the discharge cylinder |
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| If any abnormalities are found, replace them promptly. |
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Possible Equipment Failures and Troubleshooting
| Fault phenomenon |
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Solution |
| The material suction machine cannot start. |
PLC corresponding output point damaged |
Under startup conditions, the corresponding PLC output should light up. Measure whether there is 24V voltage at the output point relative to DC 0V; if not, replace the PLC transistor. |
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The intermediate relay light is not on. |
Measure whether there is 24V voltage on pins 13 and 14 of the intermediate relay. If yes, replace the intermediate relay; if no, check whether the upstream control signal has a broken wire. |
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The AC contactor failed to engage. |
Measure whether there is 220V AC voltage between terminals A1 and A2 of the AC contactor. If yes, replace the AC contactor; if not, check whether the upstream control wire is broken. |
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Thermal relay operates |
Measure whether the three-phase resistances of the motor are equal and whether the insulation resistance is greater than 0.5 MΩ. If either of these checks reveals an issue, it indicates that the motor is abnormal. |
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Wind turbine blade seized |
Replace the fan |
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Emergency stop switch not reset |
Twist the button to pop it back into place. |
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Three-phase power supply phase failure |
Check the circuit and use reliable wiring. |
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Wiring terminals loose inside the electrical control box |
Check and tighten the screws. |
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Fan motor damaged |
Replace the fan |
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Contactor damaged |
Replace the contactor |
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| Material handling abnormality |
The compressed air supply is unstable. |
Stable gas supply |
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The negative-pressure pipeline and accessories are not installed correctly, or the accessories have air leaks or are damaged. |
Properly install the negative-pressure pipes and accessories, and replace any leaking or damaged components. |
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Damage to material transfer pipes and accessories |
Replace the material delivery pipe and accessories |
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The lid of the suction hopper isn't sealed tightly. |
Secure the bucket lid. |
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The discharge flap of the suction hopper cannot be closed tightly or is damaged. |
Replace the material-suction bucket discharge flap |
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The air and material shut-off valve cylinder is damaged, and the rubber plug fails to seal tightly. |
Replace the air and material shut-off valve cylinder and rubber plug. |
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Hopper filter clogged |
Clean the filter element |
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A damaged high-level material level gauge may cause material to surge upward (if applicable). |
Replace the level gauge |
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Weight module malfunction causes material overfilling (if applicable) |
Replace the weighing module |
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The parameter setting is incorrect. |
Set the correct parameters |
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The excessive feeding rate caused the pipe to become clogged. |
Adjust to the correct feeding rate |
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| Except the VOC system, no heating is applied. |
Circuit breaker trips |
Close the circuit breaker |
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The fuse in the power regulator has blown. |
Measure whether the three-phase resistances of the electric heater are equal and whether the insulation resistance is greater than 0.5 MΩ. If not, it indicates a problem with either the electric heater itself or the wiring. Next, check if the thyristor in the power regulator is damaged. If the fuse has blown, it suggests an abnormality in the downstream circuit—proceed with caution when inspecting further. |
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Power regulator damaged |
Replace the power regulator |
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Electric heating tube damaged |
Replace the electric heating tube |
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Thermocouple damaged |
Replace the thermocouple |
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Wire connector loose |
Check and tighten the screws. |
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The parameter setting is incorrect. |
Set the correct parameters |
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| Materials melt and clump together |
The temperature setting is too high. |
Set the correct parameters |
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Thermocouple damaged |
Replace the thermocouple |
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Power regulator malfunction |
Replace the power regulator |
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| Except for the VOC system's heating temperature being too low. |
Thermocouple damaged |
Replace the thermocouple |
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Electric heating tube damaged |
Replace the electric heating tube |
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Power regulator malfunction |
Replace the power regulator |
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