How to Maintain Explosion-Proof Frequency Converters on a Daily Basis?

Compliance Standards: GB 3836 / IEC 60079

Environmental Control (Explosion-Proof Fundamentals)

Maintaining the external integrity of the unit is essential for preventing ignition in hazardous areas.

Daily Maintenance

• Dust Management: Clear surrounding combustible dust and ensure unobstructed ventilation.

• Ambient Temperature: Maintain operating environment at ≤ 40°C.

• Seal Inspection: Check the explosion-proof sealing rings at the cable entrance for cracks or aging.

Weekly Maintenance

• Surface Cleaning: Clean the explosion-proof joint surfaces with anhydrous ethanol and a non-woven fabric.

• Prohibition: Do not use metal tools for cleaning; scratches on joint surfaces will destroy the unit's explosion-proof properties.

Core Electrical Safety Items

Regular electrical verification prevents internal arcing and heat-related failures.

Monthly Maintenance

• Terminal Torque: Tighten power and motor terminals using a torque wrench (10~15 N·m).

• Radiator Cleaning: Use compressed air to blow away dust accumulation on the radiator, especially if a temperature increase of > 15°C is observed.

Quarterly (Seasonal) Maintenance

• Insulation Resistance: Test with a 500V megohmmeter; resistance must be ≥ 5MΩ.

• Grounding Resistance: Ensure grounding resistance is ≤ 4Ω.

Heat Dissipation and Protection

Active cooling and software protections prevent the unit from becoming an ignition source.

• Cooling Fan: Monthly check for abnormal noise or vibration.

• IGBT Maintenance: Replace IGBT thermal grease every 2 years. Old paste may dry and crack, leading to catastrophic overheating.

• Function Verification: Test overcurrent, over-temperature, and short-circuit protection every six months (allowable action error ≤ 5%).

Absolute Prohibitions (Violation Leads to Explosion)

Strict adherence to these rules is mandatory to maintain explosion-proof certification.

1. No Live Opening: It is strictly prohibited to open the lid while power is connected. After powering off, wait at least 5 minutes to allow the capacitor discharge.

2. No Non-Original Parts: All replacement components (sealing rings, fasteners) must be explosion-proof certified.

3. No Parameter Overrides: Unlocking parameter upper limits without authorization will void the explosion-proof qualification.

⚠️ Ultimate Warning

Explosion-proof surface damage, heat dissipation failure, and non-standard maintenance of frequency converters are the three primary causes of industrial explosions.

Note: Daily maintenance costs represent less than 1% of the potential losses from an accident. Negligence in maintenance is equivalent to burying a bomb in your facility.