 Knowledge about maintenance (I)
1：PLC input is composed of [manual signal]+[position signal]+[pressure signal]
2：PLC output is composed of [hydraulic valve]+[ reversing valve]+[electromagnetic valve]
3：All input and output parts have one relevant point to PLC, relevant parts act, then one indicating light will turn on; indication light of output part turns on, then relevant terminal component will act.
For instance: when dial function button to manual position, X3 light of PLC will turn on, Xo light will turn on if general button is dialed. X10 light will turn on when removal matrix is removed to back original point.
When touching point of pressure gauge closes, then X12 and X14 light will turn on.
Malfunction: if dynamic matrix does not stop after reaching back original point and X10 light does not turn on →switch of original point damaged →medium relay damaged. If X10 light turns on when dynamic matrix is not at the original point →induction switch damaged.
Similar: analysis and determination of malfunction of joint meter of frontal orientation and top checkout.
Remark: as for installation, distance between induction head and removable metal body is 2 to 4mm.
Power supply can be connected after 220V two-wire switch is connected to relay in series.
Notice: repairers should check state of input parts: indication light will turn on if one part acts.
Example: under manual state, use one iron device to go nearly to induction switch then leave, light at rear part will change
Maintenance instruction of automatic machine Knowledge about maintenance (II)
【Output flow of PLC】
1. According to above flow, we know that outside terminal parts of PLC has no relevant actions within relevant period no matter it is manual maintenance or working circles. Following checkout can be carried out.
Malfunction: at back point, click [open], the hydraulic valve not acts
When hydraulic pump overloads and gives alarm, open hydraulic pump, motor will not start
- as for automatic circulation, if touching point of pressure gauge is under close state, or loop of touching point has short circuit, steam valve will not acts, which does not mean that output loop of valve has problems, touching point close will provide one signal for computer, thus heating will not occur.
- As for automatic circulation, feeding starts but blowing not, the blowing valve does not act: → +24v power supply under normal state or not→+24v fuse under normal state or not →measure coils of electromagnetic valve with multimeter→coils is burnt out→ change coils
Notice: every machine will have malfunction, relevant chargers should learn content of this brochures carefully
Happy times：
one user told us that all pneumatic valves can not be opened and he had tried all methods. Then our technician hurried up there and found that switch of booster has not been opened.
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Sum: 1) Control part of mechanical and electric machine are composed of input and output part, as well as control signal. All parts are composed of one loop or two or more loops. If you have not grasped higher repaired method, one method can be used: check out all parts one after another, whether all signals of input part are under normal state.
2) Quality of products are closely connected to raw materials, matrix, medium and production flow.
3) we have considered for practical state of users at most: teaching material style has been adopted in terms of content so that users can learn it well fast. Hope that you can grasp it well.
4) Voltage of steam, cool air and cool water must conform to standard.
Maintenance Instruction for Automatic Machine
Malfunction Table 【for reference】
Parts |
Malfunction |
Method |
Item |
Hydraulic System |
Hydraulic system can not be started |
1 Check whether three-phase voltage under normal state 2 Check touching point of thermal relay
3Check contactor is under normal state or not 4 check whether FU3 is under normal state |
1 |
No slow speed |
1 check whether coils of valve core of high pressure slow overflow valve are under normal state |
2 |
Speed is not fast |
1 Check coils and valve core of low pressure fast overflow valve are under normal state |
3 |
No reversing action |
1 Check coils and valve core of reversing valve are under normal state
2 Check whether medium relay and touching point are under normal state
3 Induction switch of back point is broken down |
4 |
Pressure is not |
Check 2 to 3 items at one time
Motor has reversed revolution |
5 |
Short period |
1 Piston inside oil cylinder is not well sealed 2 Inside part of discharging valve is leaked |
6 |
Dynamic matrix |
1 There is air inside the oil cylinder 1 Guide column is not well lubricated |
7 |
Not enough |
1 2 to 3 items checkout can be carried out at one time 2 Filter of villa is stocked |
8 |
Position Signal |
Front and back position signal |
Dynamic matrix does not stop |
1 Induction switch of back point is damaged 2 Coils of signal relay and touching point are damaged
3 Power supply L2 of induction switch has not voltage, check fuse FU3, check transformer |
9 |
As for manual action, dynamic matrix can not be opened |
Carry out 4th checkout |
10 |
Not proper feeling for automatic circulation |
Induction switch of frontal orientation is broken down |
11 |
Not stop in front of orientation machine |
1 Induction switch of frontal orientation is damaged 2 Relevant medium relay is damaged
3 Power supply L2 of induction switch has not voltage |
12 |
Protruding point |
As for whole circulation, it can not go back and not start for next circulation. |
1 Prop induction switch fails 2 Relevant medium relay is damaged
3 Power supply L2 of induction switch has no voltage |
13 |
Products is pushed out improperly |
Prop induction switch fails |
14 |
Moulding pressure signal |
Stationary or removal |
Heating period is too long |
1 Voltage of steam is too low 2 Touching point is damaged 3 meter is damaged
4 Cooper pipe or filter is stopped 5 Reversing valve is damaged, pressure of cooling air is to low |
15 |
Dynamic matrix or stationary matrix can not be heated |
Dynamic matrix or stationary matrix can not be heated |
16 |
Filling system |
Some spray gun does not open
|
1 Piston inside materials is tightened without enough lubrication. 2 Small switch connected to pipe of materials does not open or is damaged 3 Air is leaked seriously |
16 |
Spray gun can not be opened or closed |
1 Ice forms inside storage 2 Pressure of compressed air is too low
3 Reversing valve is damaged 4 coils of reversed valve is damaged 5 +24V fuse is burnt out or DC power supply has problems |
17 |
Materials-blow valve can not be opened. |
1 coils of material-blow valve is damaged 2 +24V fuse is burnt out or DC power supply has problems |
18 |
Materials-blow valve is not well closed |
1 there is something wrong with inside spring 2 Inside valve is damaged |
19 |
Under feeding state if matrix goes forward |
Supper oriented switch in front of security door loses its function |
20 |
Vacuum system |
Vacuum pump can not start up |
1 check whether three-phase voltage under normal state 2 Check whether thermal relay under normal state or not
3 Check whether contactor under normal state or not 4 Check whether FU3 fuse under normal state or not 5 check the motor |
21 |
Storage barrel can not absorb materials |
1 Enter into manual operation menu, start [vacuum pump], click [suction valve] and take observation
2 Check coils of reversing valve 3 Press manual switch on reversing valve |
22 |
Low vacuum degree |
1 Check coils of water supply electromagnetic valve of vacuum pump under good state or not 2 Properly adjust inlet quantity of water 3 Check relevant airproofing of pneumatic valve is under normal state or not |
23 |
Pneumatic valve |
Hard to start valves or speed is too slow |
Under normal voltage, put function switch to manual position, enter into manual operation menu, check all pneumatic components. Take content in page 21 for reference |
24 |
Electric system |
Hard to start motor |
Not enough phase for three-phase power supply |
25 |
Breaker stops suddenly |
1 Coils of motor are damaged or water enters 2 Touching point of contactor has short circuit or plastic casing is thrashed out. 3 transformer of power supply in control cabin is damaged or grounded. |
26 |
Security door loses its function |
1. Under manual position, open security door, press switch of PLC to see whether X 23 lights can be turned on. If not, it is damaged. |
27 |
One fuse in the electric control cabin is burnt out frequently |
Coils have short circuit |
28 |
For users: content in the table is deduced according to principle. Practical state should be analyzed according to malfunctions. We will provide you with relevant experience in the future. |
