Starter Fault Guide

The starter plays a crucial role in starting numerous electrical equipment. However, faults occur from time to time. This guide aims to analyze common faults and help with quick diagnosis and effective repair.

I. Electrical Faults
Power Supply Problems:
No input power: Check whether the power supply lines are open-circuited, whether the plugs are loose or whether the fuses are blown. For example, if the fuse is blown, it may be due to a short circuit or overload in the lines. It is necessary to check the lines and replace the appropriate fuse.
Abnormal voltage: Use a voltmeter to measure the input voltage. If it is not within the rated voltage range of the starter, it may cause the starter to fail to work properly or damage the internal components. For example, for a starter with a rated voltage of 380V, an input voltage lower than 360V or higher than 400V may cause problems.
Contact Faults:
Poor contact of contacts: This may be caused by wear, oxidation or foreign matter on the contacts. It is manifested as an increase in contact resistance, severe heating or even sparking during startup. It is necessary to clean the contacts or replace severely worn contacts.
Contact adhesion: Long-term passage of large current or frequent start-stop operations may cause the contacts to adhere. At this time, the starter cannot disconnect the circuit normally, resulting in continuous power supply to the equipment. It is necessary to carefully separate the adhered contacts and check the cause. Replace them if necessary.

II. Mechanical Faults
Damage to Transmission Components:
Gear wear: After long-term operation, the tooth surfaces of the gears in the starter may wear out, resulting in unsteady transmission, noise or even inability to transmit. Check the degree of gear wear. Slight wear can be repaired, and serious wear requires replacement.
Belt slack or breakage: If a belt drive is used, the belt may become slack or break due to aging or excessive tension. Slackening will reduce the transmission efficiency, and breakage will cause the starter to fail to work. It is necessary to adjust or replace the belt.
Electromagnetic Mechanism Faults:
Core jamming: Rust, impurities on the core surface or improper installation may cause the core to jam. As a result, the electromagnetic force cannot act normally and the starter cannot be actuated. It is necessary to clean the core surface and check the installation position.
Damage to the electromagnetic coil: The electromagnetic coil may be damaged due to overheating, moisture or insulation aging. It is manifested as abnormal resistance or failure to generate electromagnetic force. It is necessary to measure the resistance with a multimeter and replace the electromagnetic coil if it is damaged.

III. Control Circuit Faults
Relay Faults:
Relay failure to actuate: This may be due to an open circuit in the relay coil, failure of the control signal to arrive or contact faults. Check the coil resistance, control lines and contact connections, and repair or replace the relay according to the problem.
Relay misoperation: Affected by electromagnetic interference, voltage fluctuations or its own parameter drift, the relay may misoperate. Shielding, voltage stabilization and other measures can be taken and the parameters can be checked and adjusted.
Control Chip Faults:
Chip damage: Due to overvoltage, electrostatic discharge or program errors, the control chip may be damaged. This leads to confusion in the control logic of the starter or failure to work. Professional personnel are required to check it. Replace the chip and reprogram it if necessary.
Virtual soldering of chip pins: Long-term vibration or poor soldering may cause virtual soldering of chip pins. This results in interruption of signal transmission. It is necessary to resolder the pins to ensure reliable connection.

IV. Q&A Session
(I) Question: What is the reason for the starter tripping instantly at startup?
Answer: It may be due to a short circuit in the lines, a motor fault that leads to excessive current, or the operating current setting of the thermal relay being too low. It may also be due to damage or short circuit of the internal components of the starter.
(II) Question: What should be done if the starter makes excessive noise during operation?
Answer: First, check whether the transmission components such as gears and belts are loose or worn. Then check whether the electromagnetic mechanism has abnormal vibration, such as whether the core is jammed, and repair or adjust according to the problem.

V. Fault Detection Process Steps
(I) Preliminary Inspection
Observe the appearance of the starter to see if there are obvious signs of damage such as smoking, charring or shell cracking.
Listen to the running sound of the starter to judge whether there are abnormal noises such as friction sounds or electromagnetic whistling sounds.
Smell whether there is a burning smell around the starter. If there is, it may indicate that components have been burned out.
(II) Measurement of Electrical Parameters
Use a voltmeter to measure the input power supply voltage to ensure that it is within the rated range.
Use a multimeter to measure the contact resistance, electromagnetic coil resistance, etc. to judge whether they are normal.
(III) Inspection of Mechanical Components
Open the housing of the starter and check the connection and wear conditions of the transmission components, such as gear meshing and belt tension.
Check the condition of the core and coil of the electromagnetic mechanism to see if there is jamming or damage.
(IV) Detection of Control Circuits
Check the working state of the relays, including the energization of the coils and the closing of the contacts.
If there is a control chip, check the connection of the chip pins and whether the working parameters are normal.
VI. Summary
There are various types of starter faults, involving electrical, mechanical, control circuit and other aspects. Through the classification and enumeration of common faults, the summary of experience in the Q&A session and the standardized fault detection process steps, when facing starter faults, diagnosis and repair can be carried out in an orderly manner, reducing equipment downtime, improving the reliability and stability of the electrical system, and ensuring the smooth progress of production and operation.