Pang born machine maintenance work report

Background
 Pang born machine maintenance required part consists four interconnected
electrical panel board
 From these electrical panel the second(the main command operation panel)
electrical panel board are completely damaged or burned
 the third panel board also burned half parts of the board
 the main breaker became shorted
 The main cause of the damage is entrance of small metal balls in between the
main three phase of circuit breaker

Maintenance work identification for all

 First visually identify the damage parts of electrical circuit panel of the machine
 Knowing the damage parts of electrical equipment’s
 Selecting and identifying electrical equipment within its type, rating and
specification depend on its electrical manual
 Then check this electrical equipment available on market of our country. If not
identify replacing with another identical electrical equipment and to fulfill all
material needs start maintenance work

Maintenance working procedure

 Read detail its electrical and operation manuals to know parts, symbols and its
operational sequence circuit
 Removing the damage parts of electrical equipment from the electrical panel
board
 Clean the panel board and make it ready to replace by new electrical device
works within its electrical manual
 Assemble new electrical device on its electrical panel board depending on its
electrical manual and its starting sequence operation orders
 Finally install electrical and control circuit within its electrical manual sequence
circuit steps

Maintenance schedule
Stage 1

 to install electrical power and control circuit work for all damage electrical panel
board parts
 then check control circuit of four electrical panel board by giving external power
to transformer that supply for control circuit
 make it the circuit standardize with its electrical manual symbol, name and
numbering
Stage 2

 testing both power and control of four electrical panel board by giving its source
power
 to identify all the machine part and give each parts limit switch and pressure
switch to the controllers that include on electrical circuit diagram
 check and test all electrical drivers, solenoid valve, sensors working or not as
electrical standard
 check and make maintenance services all mechanical drivers
 finally test electrical control circuit with its drivers by connecting power control
circuit and drivers

Stage 3

 overall machine mechanical and electrical part testing and commissioning

 N.B
 after stage 1 maintenance work progress additional mechanical group and
trained operators work before on this machine recommended to join with
electrical group

Feature limitation of maintenance works

 The is no machine operation manual
 No trained operator that operate before on this machine recently to know the
machine background history
 Difficult to now machine parts name and whether the machine parts accessory
are available or not
 Pang born Maintenance work description

Required Required material

Maintenance Electrical
NO rating electrical Remark
required parts device items quantity
circuit
Auxiliary
Control
1 Auxiliary relay 20A relay 1
circuit
contactor
Breaker 1
2 Rotary valve motor 3HP DOL contactor 1 Starting, stopping
overload 1 and emergency
Breaker 1 pushbutton
contactor 3 Selector switch
3 Exhauster motor 50HP YD
overload 1 Light indicator
timer 1 Pressure switch
Breaker 1 Limit switch
Roto contactor 3 Include electrical
4 motor 30HP YD
conditioner overload 1 circuit
timer 1
breaker 1
5 Elevator no 1 motor 7.5HP DOL contactor 1
overload 1
contactor 1
6 Elevator no 2 motor 4HP DOL
overload 1
contactor 1
7 Screw conveyer motor 1HP DOL
overload 1
Magnetic contactor 1
8 motor 0.15HP DOL
separator overload 1
contactor 1
9 Separator screw motor 7.5HP DOL
overload 1
Oscillation contactor 2
motor 2KW DOL
screen vibrator overload 2
contactor 1
10 Hook rotation motor 0.75HP DOL
overload 1
11 Blower motor
12 Enter door Solenoid valve FRDOL –car
13 Exit door Solenoid valve Electrical control circuit Interconnection work required control
14 reclamation Solenoid valve with electrical panel board part three and four circuit
15 Blasting motor by timers and overload relays to make the
16 Car Motor process sequential coordination
17 Last cycle command
19 Timer Card
 DOL direct online circuit All Include
 YD star-delta circuit electrical power and
NB
 FRDOL forward reverse direct online circuit control circuit
installation work
 Machine maintenance part, operation process and starting sequence
methods depending on machine electrical diagram

Breaker LS1

SL1 EH1

Auxiliary contact relay EH2

LS2 PR1

PS1 DOL

PS2 Rotary valve

LS1 RT1

PS3
YD
PS4 Exhauster
FC1
LS2
TM

RT2
DOL YD
PS5
FC2
Elevator no1 PS6 Roto conditioner
TM
RT3 LS3
Reclamation RT4

DOL PS5 DOL

Screw conveyer PS6 Magnetic separator
RT5
LS4 RT6

DOL PS6 DOL

Elevator no 2 PS8 Separator screw,
RT7 LS5 vibrating screen RT8
PS9
PS10 Hook pre selector Auxiliary relay contact

LS6
Blower Hook rotation

Exit Door Entrance

Reverse Car Forward

Other steps Check on testing &commissioning time

 Stage 1 maintenance work progress

Types of work progress (%)

Maintained
NO Electrical device Remark
machine parts
Power circuits Control circuits

1 Auxiliary relay 99
2 Rotary valve motor 99 99

3 Exhauster motor 99 99
4 Roto conditioner motor 99 99 Pressure switch and
5 Elevator no 1 motor 99 Limit switch will
Include electrical
6 Elevator no 2 motor 99 control circuit on
7 Screw conveyer motor 99 99 stage 2 work
schedule
Magnetic
8 motor 99 99
separator
9 Separator screw motor 99 99
10 Hook rotation motor 99 99
11 Blower motor 99 99
Oscillation screen
motor 99 99
vibrator
12 Enter door Solenoid valve 99 Oscillation screen
vibrator have two
13 Exit door Solenoid valve 99
motors and this two
14 reclamation Solenoid valve 99 motors not work,
15 Blasting Circuit 99 needs coil
rewinding
16 Car motor 99 99
maintenances
17 Last cycle Circuit 90
19 Timer card 99
 From stage one, maintenance works: - The remains work is to make the circuit standardize
with its electrical manual symbol, name and numbering. This work requires below
mentioned
 Command push button panel putting holes need mechanical modification
N.B  Cable duct, cable hose, symbols and numbering tags, cable holder kit and cable tay
Important to make the circuit standardize
 some old electrical device recommend to replace with recent electrical standard
device
 Stage 2 maintenance work progress

Work
NO Description of maintenance works progress Remark
(%)
Testing both power and control of four electrical No load test
1 panel board by giving its source power
99
give each parts limit switch and
To identify all the machine part and give each
pressure switch to the controllers
2 parts limit switch and pressure switch to the 90 work will done on stage one
controllers
standardize circuit work
*some valves and sensors
Check and test all electrical drivers, solenoid recommended to change
3 valve, sensors working or not as electrical 80 *vibrating screen 2KW motor
standard required to rewind the coil

lubrication, cleaning, gear box,

Check and make maintenance services all pneumatic piston, belt and chain
4 mechanical drivers
90 servicing works and mechanical
modification work
Finally test electrical control circuit with its Ready to commissioning work with
5 drivers by connecting power control circuit and 90 load test
drivers

Required materials to standardize the maintenance work as electrical

circuit manual
NO Material description spec Unit qty Remark
1 Cable duct 50mm M 2
2 Control cable hose 25mm M 3
Symbol Packet 1
3 Line indicator tag
number Packet 1
4 Control cable holder kit standard Packet 1
5 Cable tie 6mm Packet 1
6 Connector 12 pin No 4
25A No 9
Recommended to
32A No 9
7 Fuse replace by breaker
80A No 9
400A No 4
Recommended material to replace by new
1 Basting contactor 80A No 1
80A No 2 Recommended to
2 Blasting dropout fuse box
32A No 4 replace by breaker
3 Pneumatic piston relay 110V No 10
Auxiliary contactor 110V No 4

Pang born Control button and indicator arrangement orders depending on its electrical diagram
 Elevator no 1 Screw conveyer
Auxiliary Rotary valve Exhauster
Roto conditioner Magnetic separator
LS 2 LS 3 LS 4 LS 7 LS 8

S1 1PB 2 1PB 4 1PB 6 1PB 8

EM 1 0PB 1 0PB 3 0PB 5 0PB 7

Elevator no 2,
Sand pressure separator & screw Hook rotation
Hook rotation Blowing
Maximum level conveyer load pre-selection
vibrating screen

LS 9 LS 10 LS 11 LS 5
LLS 1
Roto blasts start
Abrasive reserve 1PB 10 1PB 12 S2
1PB 14
Maximum level

LLS 2 0PB 9 0PB 11 0PB 13 Reclamation

Entery door Exit door

LS 6
0pen Close Open Close

1PB 15 1PB 16 1PB 18 1PB 17 S3

Car
Blasting Last cycle Timer
Forward Backward

KS 12 1PB 19 1PB 20 S 13 S

LS Light indicator
S Selector
1PB Start push button
Legend 0PB Stop push button
LLS Level light indicator
KS Key selector
EM Emergency

Stage 3 maintenance work progress

 Ready to commissioning work with load test

Stage 3 limitation of maintenance works
 Required materials to standardize the maintenance work as electrical
circuit manual not delivered
 Oscillation screen vibrator motors not work, needs coil rewinding
maintenances
 Manufacture Basting blades with furnace mold is not delivered
 Command push button panel putting holes need mechanical modification
but they didn’t work any modification

40 ton over head crane maintenance work

Background history
  The crane have two host and trolley and one interlock with travel car PLC
command pane boards
 The first problem of this crane is host one become stop working operation,
because of host one exceed working operation limit and interlock PLC command
became lockout the system
 The technical group try to solve the problem by install direct external control
circuit that out of its operating system
 Finally main interlock PLC safety command lockout all system operation,
because of system short circuit problem

Crane maintenance work procedure

 Read detail its electrical and operation manuals to know parts, symbols and its
operational sequence circuit
 Removing the external wire that install direct control circuit
 Replace its control line installed circuits depending on its electrical control
wiring manual.
 After replacing its control system began to solve then short circuit problem by
tracing each control line and make and make continuity test on each control line
without any power supply.
 Finally make rest main interlock PLC control command and configure default
parameter setting.
 Then lastly test and check by operating each parts marking by its operation
system and solve the remaining problem (if Occur) as its electrical control
standard.

Recommended operation instruction steps

1. Start by pull-up the emergency button from its control joystick.
2. Then the system starts diagnosis test overall system for 10s (do not touch any
push button until 10s)
3. After 10s check interlock angle selector switch at OFF (pull back) position. Then
you can select one of the hoists by two key selector position switch
4. If you want two hoist work at the same time interlock angle selector switch at ON
(push front) position.
 During hosting up time, the host winch do not exceed to the car travel
bridge (the maximum limit of host hock up to 50cm nearest to car
bridge)
 When doing host up the material, run it by slow speed up to the
material leave to the ground
5. At the end of operation work stop the crane by pushing down emergency button
6. If you want to operate the crane again, start based on crane recommended
operation instruction Steps.

NO Crane Class Maintenance work description Remark

section Operation Auto Work
 operating
parts progress
speed
Slow Completed
Forward
1 Car travel Fast Completed
Slow Completed
Reverse
Fast Completed
Left Slow Completed
Trolley
2 Host 1 Right Fast Completed
up Slow Completed
Host
Down Fast Completed
Left Slow Completed
Trolley * Work with modification
3 Host 2 Right Fast Completed (not permanent)*
Up Slow 95 %  Spare part not deliver
Host
Down Fast 95 %
Forward Slow completed  Its manufacturer
Fast completed interlock selector
Car
Slow completed switch not available in
Reverse our country markets
Fast completed
Slow completed  This selector replaced
Left by one key selector
Fast completed
4 Interlock Trolley switch for two hosts
Slow completed
Right selection and one
Fast completed
Slow completed angle selector for
Up interlock selection
Fast completed
Host
Slow completed
Down
Fast completed
 N.B All maintenance works done by crane instruction operating system

40 ton over head crane maintenance work description progress

Sand mold (mechanized) machine maintenance report

Background History
  Sand mold machine process control with PLC command panel board
 The first problem of this machine is roller 3 one of the machine parts fail to run
or stopped working
 The electrical group try to solve the problem but problem solving method get all
electrical parts become short circuited
 In the case of short circuit, then electrical device (power supply, one PLC output
module and some proxy sensor) completely damaged.
 In the above case the control cables that install underground manhole cable line
also become shorted because of water accumulation in underground manhole.

Mechanized machine maintenance work procedure

 Read detail its electrical and operation manuals to know parts, symbols and its
operational sequence circuit
 Began to solve the short circuit problem by tracing each control line and make
continuity test on each control line without any power supply.
 Replace damaged electrical device circuits depending on its electrical wiring
diagram manual rating
 Finally make disconnect the ground line that install underground manhole cable
line and install new external ground line to hydraulic solenoid and sensor line
 In case of one PLC output module damage replaced by install control sequential
electrical circuit with relay contact points
 Then lastly test and check by operating each parts with its operation system and
solve the remaining problem (if Occur) as its electrical control standard.

Sand mold (mechanized) machine maintenance work description

progress

NO Machine parts class Maintenance work Remark

 description
Semi-Auto Work
operation progress (%)
Roller done 90 Proxy limit switch work
Belt roller done 90 will done after
1 Cars commissioning period
Trolley done 90
Limit switch done 90 that to know which parts
need auto operation for
2 Rollers Roller done 90 doing safe work situation
motor done completed
Roll over close/open done completed
Roll over on/return done completed
3 Hydraulic Plate change in/out done completed
Roller done completed
Belt roller done completed
sensors done completed
motor done completed
4 Vibrator
Pneumatic done On progress
5 Mold delivery belt belt done completed
 Its power supply replaced by new and additional relay(from store) used for sequential circuit
 N.B This machine ready to work by its manual instruction operating system

N Material used for Estimation Total

Machines Quantity
O maintenance work cost estimation
Breakers 5 25,000
contactors 10 60,000
1 Pang born timers 5 20,000 130,000
Push button 12 6,000
Overload relay 10 20,000
Power supply 1 20,000
2 Mechanized Mechanical limit switch 6 6,000 65,000
Proxy limit switch 8 32,000
contactor 1 5,000
3 40 ton crane Auxiliary 4 2,000
7,000
Including the remains pang born machine required materials to standardize the
maintenance work
Grand total estimation cost 200,000 – 250,000
Estimation cost of Materials used for maintenance work