As the key equipment for particle characterization, the stable operation of spray particle size analyzer directly affects the reliability of experimental data. The following are solutions for typical faults, covering the entire process management from emergency handling to long-term maintenance:
1、 Abnormal test results
Severe data fluctuations/poor repeatability
Cause positioning: ① Environmental vibration exceeding the standard leads to light path deviation; ② The sample concentration exceeds the detection range; ③ The circulating pump generates bubble interference.
Disposal plan: Activate the shockproof workbench and fix the instrument; Adjust the sample concentration to a reasonable range of shading rate according to the standard curve; Start the ultrasonic degassing program to eliminate bubbles. If wet testing is used, it is necessary to ensure that the dispersant is fully decomposed.
The overall particle size is either too large or too small
Core diagnosis: ① Lens contamination causing scattered light distortion; ② The calibration parameters have not been updated with the replacement of the medium.
Corrective measures: Dip a small amount of ethanol into a mirror paper and wipe the measurement window unidirectionally; Re calibrate the standard particles, paying special attention to parameter reset when replacing media with different refractive indices.
2、 Hardware system malfunction category
Power on but no response
Classification inspection: ① Check for poor contact of the fuse holder; ② Loose control panel wiring; ③ The emergency stop button has not been reset.
Operation guide: Disconnect the peripheral devices in sequence to isolate the fault source, and focus on checking the status of the LED indicator lights on the main control board. Press and hold the reset button until the buzzer sounds, restore the factory default settings, and then try turning on the device.
Circulating pump abnormal noise/insufficient flow
Mechanical disassembly: ① Blockage of the filter screen leading to dry burning; ② The lack of oil in the gearbox causes metal friction.
Repair steps: Remove the inlet pipe and clean the 3 μ m pre filter; Add food grade silicone oil to the oil injection hole of the pump body; If the impeller is severely worn, it is necessary to replace the spare parts and perform dynamic balance correction.
3、 Special issues related to optical systems
Laser does not emit light/power is unstable
Energy chain inspection: ① Temperature control imbalance caused by cooling fan failure; ② End of life of laser tube; ③ Voltage fluctuation of power module.
Emergency response: Immediately shut down the entire machine to prevent overheating and damage, and replace the backup laser; Adjust the power supply voltage to within the required ± 5% range of the equipment.
The detector signal is weak
Key points for optical path calibration: ① Adjust the alignment of the transmitting and receiving optical axes; ② Clean up the dust accumulation on the inner wall of the integrating sphere; ③ Verify the zero drift of the AD converter.
Performance verification: Use standard latex balls for span verification to ensure that the recovery rates of the three characteristic particle size points are within ± 3%.
4、 Special working condition response strategy
Protection against high humidity environment
Construction of moisture-proof system: Install dehumidifier to control environmental humidity below 60%; Preheat for 30 minutes before starting up daily to dispel internal moisture; Spray nano waterproof coating on key circuit boards.
Corrosive sample processing
Protection upgrade plan: using Hastelloy measuring units; Replace with corrosion-resistant pipeline joints; After the experiment, perform three or more solvent flushing procedures, and finally blow the flow channel with dry air.
5、 Long term maintenance mechanism
Establish a quarterly maintenance system: ① Replace the dust filter element; ② Calibrate full-scale linearity; ③ Check the degree of aging of the sealing ring. Save complete maintenance logs, record each fault code and handling process. Newly purchased consumables must undergo compatibility testing, especially cross validation of standard samples from different batches.