Motor failure is the most common electrical problem and should be handled according to the "power-off detection - fault location - repair/replacement" process. When the motor fails to start, first check if the power switch has tripped. If it trips and then trips again after being reset, it's likely a short circuit in the motor. Use a megohmmeter to test the motor's insulation resistance. If the resistance is <0.5MΩ, it indicates a short circuit in the windings, requiring professional electrician repair. If the motor makes abnormal noise and gets hot after starting, the bearings may be lacking lubrication or damaged. After disconnecting the power, remove the motor end cover, inspect the bearings, and add food-grade lubricant or replace the bearings. When the motor stops due to overload during production, first check for mechanical faults (such as equipment jamming), fix them, and then reset the overload protection switch to avoid frequent starts that could damage the motor.
Troubleshooting wiring and control cabinet faults requires attention to detail. When a short circuit occurs, focus on checking the equipment's inlet terminals and wiring terminals. If the insulation is found to be burnt, replace it with flame-retardant wire of the same specification, rewire, and tighten the terminals. If the control cabinet indicator lights are not lit, first check the main power supply and fuses. If the fuse is blown, replace it with a matching specification (do not use copper wire as a substitute). If the indicator lights are damaged, ensure the power is disconnected before replacement to avoid short circuits. When the PLC control system malfunctions, first restart the control system. If it still cannot be restored, re-import the backup program and contact the equipment manufacturer for remote assistance to avoid modifying the program yourself, which could lead to system instability.
Handling electrical faults must strictly adhere to safety regulations. Before any operation, the main power supply must be disconnected, a "Do Not Operate" sign must be displayed, and a voltage detector must be used to confirm no power. When troubleshooting the control cabinet, wear insulated gloves and use insulated tools to avoid direct hand contact with wiring terminals. In damp environments (such as raw material cleaning areas), wear insulated shoes to prevent electric shock from leakage. Non-professionals are strictly prohibited from disassembling core electrical components such as motors and frequency converters; these operations must be performed by a certified electrician.
The core of preventing electrical faults is establishing a "regular inspection and maintenance" system. Daily inspections are conducted for damaged wiring and loose terminals; dust is cleaned from the control cabinet weekly, and the cooling fan is checked for proper functioning; insulation tests are performed monthly on motors and frequency converters; and a comprehensive electrical system overhaul is carried out annually, replacing aging wiring and components. By strictly implementing this inspection system, a feed mill reduced its electrical fault rate by 85%.
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