JP2012160923A - Repair method for apparatus and substrate for repair - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve the following problem: If any of difficult-to-obtain relays used on a control substrate is failed, the control substrate is usually replaced with a new control substrate for repair; therefore, even when only one relay is failed, all the relays needs to be replaced, however, repair itself becomes difficult because they are difficult to obtain.SOLUTION: A substrate for repair with a relay for repair that functions in place of a failed relay is connected to a connector for inspection, an on-off command to the failed relay is always monitored, and the relay for repair is turned on and off, interlocking with the on-off command to the failed relay.

Description

  In the present invention, when a plurality of relays for turning on and off energization to a plurality of loads such as a motor built in a device such as a hot water supply device are attached to one control board, The present invention relates to a repair method performed when a failure occurs and a repair substrate used for the repair.

  In the case of a device having a built-in load such as a motor through which a relatively large current flows, a relay is used to turn on / off the power to the load (see, for example, Patent Document 1).

  Generally, a plurality of loads are built in a device, and a relay is provided corresponding to each of the plurality of loads, and the plurality of relays are mounted on one control board. A microcomputer is attached to the control board, and the microcomputer turns on and off the relay according to the procedure of the control program stored in advance.

  On the other hand, in order to inspect the operating state of the device, the control board is provided with an inspection connector. When an inspection device is connected to the inspection connector, the inspection device can read the control content on the control device side. For example, if any of the relays is on, the inspection device can read that the relay is on. If the relay is off, the timing after the relay is off. It can be detected that the relay is turned off by reading the inspection device. Therefore, when the reading on the inspection apparatus side is continuously performed, the on / off state of each relay can be detected in real time.

Japanese Patent Laid-Open No. 5-322325 (page 5-7, FIG. 1)

  A relay is used for the conventional control board, but in recent years, a power control element having a large capacity has been developed, and there is a tendency that the relay is not used for a newly designed control board. Therefore, it tends to be difficult to purchase relays in the market.

  However, devices with built-in control boards designed using relays are still in use. And if one of the relays on such a control board fails, it will usually be repaired by replacing the control board with a new control board, but all but one relay has failed If the relay is replaced, and it becomes difficult to obtain the relay, there is a problem that the repair itself becomes difficult. It is practically impossible to remove the failed relay from the control board at the repair site and attach a new relay to the control board.

  In view of the above problems, an object of the present invention is to provide a method for repairing a control board provided with a plurality of relays when any one of the relays fails, and a repair board used for the repair. .

  In order to solve the above problems, a device repair method according to the present invention is a control board that controls a device incorporating a plurality of loads, and includes a relay for turning on and off each load for each load. A repair relay that functions as a substitute for a faulty relay is provided in a method for repairing when any of the relays is disabled due to an inspection connector for reading the control contents. A repair board is connected to the inspection connector, an on / off command to the failed relay is constantly monitored, and the repair relay is turned on / off in conjunction with the on / off command to the failed relay.

  In order to turn on / off the repair relay from the control board side to the repair board, it is necessary to give such a function to the control board in advance assuming a failure. In most cases, such functions are not provided. In the above repair method, a normal relay other than the faulty relay is obtained by constantly monitoring the on / off command from the repair board side to the faulty relay and turning the repair relay on and off in conjunction with the on / off command for the faulty relay. Activating the repair relay instead of the failed relay without replacing the

  Further, the repair board according to the present invention is a control board for controlling a device incorporating a plurality of loads, and is provided with a relay for turning on and off energization of each load for each load and for reading the control contents. When a failure that disables use of any of the relays occurs, a connection port that connects to the connector for inspection and a repair relay that functions as a substitute for the failed relay are provided in the case where an inspection connector is provided. The on / off command to the failed relay is constantly monitored, and the repair relay is turned on / off in conjunction with the on / off command to the failed relay.

  As is apparent from the above description, the present invention failed with one control board with a plurality of relays attached, instead of replacing the entire control board when one of the relays fails. Repair is performed by adding a repair board with a repair relay that replaces the relay, so even if it becomes difficult to obtain relays, repair is performed using only the minimum number of relays. be able to.

The figure which shows the structure of one embodiment of this invention Block diagram showing the structure of the control board Block diagram showing the structure of the repair board

  Referring to FIG. 1, reference numeral 1 denotes a hot water supply apparatus to which a repair method according to the present invention is applied. In the hot water supply device 1, a load such as a motor 11 that drives a circulation pump and other electromagnetic valves (not shown) are incorporated as loads. The operation of these loads is controlled by the control board 2. Reference numeral 12 denotes an earth leakage breaker interposed between the drive power supply and 3 denotes a repair substrate described later.

  Referring to FIG. 2, one power supply line 12 a among the power supply lines that have passed through earth leakage breaker 12 is directly connected to motor 11, and the other is connected via relay 22 attached to control board 2. Yes. Reference numeral 20 denotes a power supply line for connecting the relay 22 and the motor 11.

  As described above, the hot water supply device 2 includes a load in addition to the motor 11, and energization of loads other than the motor 11 is performed via the other relays 23. The plurality of relays 22 and 23 are on / off controlled by a CPU 21 which is a microcomputer provided on the control board 2.

  Since a relatively large current flows through the motor 11 even in the load, the contact of the relay 22 tends to deteriorate more easily than the contact of the other relays 23. Therefore, if the relay 22 breaks down, the motor 11 cannot be controlled. Usually, in such a case, repair is performed by replacing the control board 2 with a new control board 2, but in the present invention, repair is performed without replacing the control board 2 by adding the repair board 3. Do.

  The control board 2 is provided with an inspection connector 24 to which an inspection device is connected. When an inspection device (not shown) is connected to the inspection connector 24, various inspection commands are output from the inspection device side, and the inspection device reads data in the control board. For example, the type of control board, the operation history of each load, and the operation status of each load at that time can be read on the inspection device side.

  Referring also to FIG. 3, the repair board 3 is provided with a CPU 31, which is configured to be able to communicate with the control board 2 via the serial communication circuit 34. In addition, two relays 32 and 33 that replace the relay 22 are attached to the repair board. The two relays 32 and 33 are connected in series and have higher redundancy than the control board using the single relay 22. Each relay 32 and 33 is provided with a contact monitoring circuit. When an abnormality occurs in the contact of the relays 32 and 33, for example, when the relay 32 and 33 are stuck and cannot be restored to the off state while being energized. On the other hand, when it is not turned on after being turned off, the CPU 31 can detect the abnormality as an abnormality of the contact. 32a and 33a are relay drive circuits, and 35 is a safety circuit.

  As described above, when an abnormality occurs in the relay 22 of the control board, the repair board 3 is connected to the inspection connector 24 and the on / off state of the relay 22 is constantly read from the control board 2. Although this reading is performed at a predetermined cycle, the cycle is several milliseconds, and problems such as time lag do not occur in practice. Then, the power supply line 20 is removed, and power is supplied to the motor 11 through the power supply line 30 from the leakage breaker 12 via the relays 32 and 33.

  The CPU 21 of the control board 2 does not detect that the relay 22 has failed, and outputs an on / off signal to the relay 22 assuming that the relay 22 is operating normally. However, since the power supply line 20 is disconnected and the relay 22 does not operate normally, power is not supplied to the motor 11 via the relay 22. On the other hand, since the control board 2 is monitoring the control status on the repair board 3 side, when an ON signal is output to the relay 22, it is read and the relays 32 and 33 are turned on. Then, electric power is supplied to the motor 11 via both relays 32 and 33, and the motor 11 is driven. Further, when an off signal is output to the relay 22 to stop the motor 11 on the control board 2 side, it is detected on the repair board 3 side and the relays 32 and 33 are turned off. As a result, the supply of power to the motor 11 is stopped, and the motor 11 stops. In addition, it is configured so that the repair board 3 can detect other troubles in addition to the abnormality of the relays 32 and 33, and when any abnormality occurs, the repair board 3 stops the control board 2. It is also possible to stop the operation of the entire hot water supply device 1 by transmitting a command.

  In addition, this invention is not limited to an above-described form, You may add a various change in the range which does not deviate from the summary of this invention.

DESCRIPTION OF SYMBOLS 1 Hot-water supply apparatus 2 Control board 3 Repair board 11 Motor 22, 23, 32, 33 Relay

Claims (2)

  A control board that controls a device incorporating a plurality of loads, provided with a relay for turning on and off the power to each load for each load, and provided with an inspection connector for reading the control contents, In the method of repairing when any of the relays becomes unusable, a repair board having a repair relay functioning as a substitute for the failed relay is connected to the inspection connector, and A method of repairing a device characterized by constantly monitoring an on / off command and turning on / off a repair relay in conjunction with an on / off command for a failed relay.   A control board that controls a device incorporating a plurality of loads, provided with a relay for turning on and off the power to each load for each load, and provided with an inspection connector for reading the control contents, When a failure that makes any of the relays unusable occurs, it has a connection port that connects to the inspection connector and a repair relay that functions as a substitute for the failed relay. A repair board characterized by monitoring and turning on / off a repair relay in conjunction with an on / off command for a failed relay.

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