The laboratory fully automatic bottle washing machine is an efficient equipment for cleaning glassware, but it may malfunction due to improper operation, water quality issues, or mechanical wear during long-term operation. The following summarizes common faults and solutions from modules such as water inlet system, sprinkler system, heating system, control system, mechanical transmission, drainage system, etc., to help quickly troubleshoot and repair.
1、 Water inlet system malfunction
1. Fault phenomenon
-The water injection time is too long or cannot be injected normally.
-The water flow is unstable and intermittent.
-The clogged inlet filter leads to insufficient water flow.
2. Cause analysis
-Insufficient water pressure of the water source (below 0.2 MPa).
-The inlet filter is clogged with impurities such as particulate matter and microbial membranes.
-Electromagnetic valve malfunction or water inlet pipeline leakage.
3. Solution
-Check water pressure: Install a pressure regulator valve or booster pump to ensure stable water pressure.
-Cleaning the filter: Disassemble the inlet filter, clean the blockage with a soft bristled brush, and clean it regularly every month.
-Test solenoid valve: Use a multimeter to check if the solenoid valve coil is energized, and replace the damaged solenoid valve.
-Check for pipeline leaks: Check for loose water pipe joints and replace aging sealing rings.
2、 Spray system malfunction
1. Fault phenomenon
-The spray arm rotates unevenly or does not move.
-The nozzle is blocked, causing some areas to have no water flow.
-After cleaning, there are residual water stains or dirt on the utensils.
2. Cause analysis
-Rusting of spray arm bearings or motor failure.
-Calcium and magnesium ions in water scale and block the nozzle aperture (especially in hard water areas).
-Improper detergent ratio or incomplete washing procedure.
3. Solution
-Cleaning the nozzle: Disassemble the nozzle, use a needle or ultrasonic cleaning machine to remove scale, and regularly check the nozzle aperture.
-Lubricating bearings: Disassemble the spray arm, clean the rust, and apply food grade lubricating oil.
-Adjust washing parameters: Add neutral detergent according to the manufacturer's recommended ratio and increase the number of pre wash or rinse cycles.
-Replace motor: If the motor is damaged, contact the manufacturer to replace it with a dedicated waterproof motor.
3、 Heating system malfunction
1. Fault phenomenon
-The water temperature cannot reach the set value (such as above 80 ℃).
-The heating indicator light is abnormal, but the device is still running.
-Scaling on the surface of the heating tube leads to overheating protection.
2. Cause analysis
-Heating tube aging or temperature control sensor failure.
-The accumulation of scale leads to a decrease in thermal efficiency.
-Poor contact of heating circuit or disconnection of fuse.
3. Solution
-Cleaning scale: Soak the heating tube in citric acid or a specialized descaling agent to avoid scratching with sharp tools.
-Detecting sensors: Compare the actual water temperature with the displayed value using a calibrated thermometer, and replace the faulty sensor.
-Check the circuit: Confirm that the power supply wiring of the heating tube is secure, and replace the blown fuse.
-Replace heating tube: If the heating tube is damaged or the power attenuation exceeds 30%, it needs to be replaced as a whole.
4、 Control system malfunction
1. Fault phenomenon
-Touch screen unresponsive or program disrupted.
-Abnormal cleaning cycle (such as ending prematurely or extending indefinitely).
-The door is not tightly closed but the equipment is still running.
2. Cause analysis
-PLC program crashes or touch screen malfunctions.
-The door control sensor is misaligned or obstructed by foreign objects.
-Relay adhesion causes a short circuit in the circuit.
3. Solution
-Restart the system: Turn off the main power for 10 seconds and then restart it, attempting to restore the factory settings.
-Calibration sensor: Adjust the position of the door control photoelectric sensor and clean the dust on the surface of the sensor.
-Update firmware: Contact the manufacturer to upgrade the control program and fix software vulnerabilities.
-Replace touch screen: If the screen is physically damaged, it needs to be replaced with a touch panel of the same model.
5、 Mechanical transmission failure
1. Fault phenomenon
-Conveyor belt offset or stuck bottle.
-The cabin door is not tightly closed or the sealing strip is deformed.
-The motor runs but the vessel does not move.
2. Cause analysis
-Insufficient tension of the conveyor belt or worn track.
-The aging of the sealing strip leads to air leakage.
-Wear of transmission gears or belt breakage.
3. Solution
-Adjust the conveyor belt: Loosen the tension screw, manually adjust the position of the conveyor belt, and tighten it.
-Replace sealing strip: Disassemble the old sealing strip and replace it with a high-temperature resistant silicone strip (matching the original size).
-Check gears/belts: Clean the gear teeth and debris, and replace the severely worn synchronous belt.
6、 Drainage system malfunction
1. Fault phenomenon
-Slow drainage speed or inability to drain.
-Overflow or leakage of drainage pipes.
-The drainage pump makes abnormal noise but does not operate.
2. Cause analysis
-The drainage pipe is bent or the filter screen is blocked.
-The impeller of the drainage pump is stuck by hair and glass debris.
-The malfunction of the float switch resulted in incorrect drainage signals.
3. Solution
-Clearing the pipeline: Disassemble the drainage pipe and clean the debris (such as glass shards and rubber fragments) in the filter screen.
-Disassemble the drainage pump: remove the impeller entanglement and add lubricating oil.
-Replace the float switch: Test whether the float action is flexible, and if necessary, replace the sealed float switch.
7、 Preventive maintenance recommendations
1. Daily check
-Clean up detergent residue and wipe off water stains in the cabin.
-Check the integrity of the door seal and clean the surface of the sensor.
2. Weekly maintenance
-Run the no-load program to check the rotation and heating function of the spray arm.
-Clean the inlet filter and drainage filter.
3. Monthly maintenance
-Clean the heating tube and spray system with descaling agent.
-Check the tension of the conveyor belt and motor noise.
4. Annual maintenance
-Replace the aging sealing strip, solenoid valve, and heating tube.
-Fully calibrate temperature and pressure sensors.