As the core tool for testing power equipment, the stability and accuracy of photovoltaic DC high current generators directly affect the reliability of test results. To ensure the long-term efficient operation of the equipment, a systematic maintenance plan covering daily inspections, regular maintenance, and fault prevention needs to be established.

1、 Daily inspection and basic maintenance

1. Appearance and connection inspection

Before daily use, check whether the equipment casing is complete and whether the cables connecting the control box and the host are damaged or loose. Focus on checking whether the output copper bars and grounding terminals are in good contact to avoid heating or sparking caused by poor contact. For example, a certain photovoltaic laboratory once had a loose grounding wire6000ALocal overheating occurred during high current testing, almost causing equipment damage.

2. Operating environment monitoring

Ensure that the equipment is placed in a well ventilated environment around0.5There is no obstruction within the meter. Regularly clean the dust at the inlet of the cooling fan to prevent the host temperature from being too high due to air circulation obstruction. The ambient temperature should be controlled within-10℃to40℃Between, the humidity should not exceed85%To avoid condensation affecting electrical performance.

2、 Regular maintenance and maintenance of key components

1. Deep cleaning of ventilation system

Blow the gap between the cooling fan and transformer winding of the host with compressed air every month, and disassemble the fan for thorough dust removal every quarter. A certain power research institute strictly implements this process to ensure that the equipment operates continuously6000AWhen outputting, the temperature of the core components decreases compared to before maintenance15℃The stability has significantly improved.

2. Electrical performance testing

Transformer calibration: Compare the output values of the transformer with a standard current source every six months, and the error exceeds±0.5%Adjust the tap or replace the component when necessary.

Pressure regulator maintenance: Check the wear of the carbon brush of the electric column pressure regulator, if the wear exceeds1/3Replace immediately to prevent voltage fluctuations caused by poor contact.

Insulation test: Measure input with a megohmmeter/The insulation resistance of the output terminal to ground should be greater than50MΩOtherwise, it is necessary to dry or replace the insulation material.

3、 Life management of core components

1. Upflow host maintenance

At the copper bar connection of the host, every time it runs200Tighten the bolts once every hour to prevent an increase in contact resistance due to thermal expansion and contraction. Regularly check the oil level of the transformer, and ensure that the oil level is below the observation window2/3It is necessary to supplement insulation oil to avoid partial discharge.

2. Control box software upgrade

Contact manufacturers annually to update control programs and optimize current regulation algorithms. For example, a certain device upgrades its current response speed from0.5Instantly increase to0.2Seconds significantly improved the efficiency of the experiment.

4、 Emergency response and preventive measures

1. Response to abnormal situations

Current fluctuation: Immediately pause the test and check the stability of the input voltage and the status of the voltage regulator.

Overheating alarm: After cutting off the power, check the operation of the fan and clean the heat dissipation channel.

Protection action: Record the fault code, investigate the cause of overcurrent and short circuit, and then reset.

2. Spare parts reserve management

3. Establish a critical spare parts inventory, including vulnerable parts such as carbon brushes, fuses, and cooling fans, to ensure that any malfunctions occur4Complete the replacement within hours. A certain photovoltaic company has implemented a spare parts pre positioning strategy to reduce equipment downtime from8Shorten hours to2hour

By implementing the above maintenance plan, the failure rate of photovoltaic DC high current generators can be reduced60%Extend the service life to the design value1.5Twice. It is recommended to establish equipment maintenance records, recording the time of each maintenance, replacement of parts, and testing data, to provide a basis for full lifecycle management.