I. Electrical Components:

The wiring of the input and output sides of the miniature circuit breaker is reversed.

The coil voltage of electrical components does not match the voltage specified in the drawings, especially common with the voltage of small relays and indicator lights, which are prone to errors.

The polarity of electrical devices is reversed. Many components within DC electrical devices, such as electrolytic capacitors, transistors, and integrated circuits, are polarity sensitive. If they are subjected to reverse voltage, they are likely to be damaged quickly.

II. Terminal Crimping:

The wire and terminal are not crimped tightly: It is crucial to ensure a tight connection between the wire and the terminal to prevent excessive contact resistance. When a large current passes through a loose connection, it may generate significant heat, accelerating the oxidation of the contact surface and further increasing contact resistance. This could cause intermittent signal transmission or even damage the device and the entire control panel in power circuits. Solution: After crimping, pull on the terminal with appropriate force to ensure it is secure. For high-power circuits, use a hydraulic crimping tool and select the correct die size for the wire gauge, reducing sizes until there is no gap between the terminal and the wire.

The wire gauge does not match the terminal size: Even if the wire seems securely attached to the terminal, the contact might only be point-to-point, resulting in high contact resistance. This can lead to the issues mentioned above. Solution: If the terminal is loose or the wire gauge does not match the terminal size, fold the wire before crimping to increase the contact area and prevent loosening.

III. Inserting Wires into Electrical Device Terminals:

Inserting the wire into the lower part of a miniature circuit breaker's terminal and tightening the screw in reverse may seem secure, but if the terminal does not fully contact the breaker's terminal post, it could result in a poor connection.

If the terminal is flipped to the side or does not match the electrical component's connection point, applying more force will not ensure full electrical contact between the terminal end and the component.

When wiring power circuits, inserting too much insulation into the electrical component can result in the wire and the component's conductive part not making full contact.

Inserting more than two wires into the same terminal of an electrical component may seem secure, but the contact area of the wires in the middle can be reduced, potentially causing overheating.

IV. Tightening During Wiring:

Do not use pliers to tighten or loosen damaged or deformed bolts and nuts, to avoid further damage. Use an adjustable wrench and ensure it is properly adjusted to prevent damaging the bolts and nuts.

If a bolt or nut is difficult to remove, do not force it, as this may deform it and make it even harder to remove. Apply a suitable loosening agent and wait before attempting to remove it again.

Ensure the screwdriver is pressed firmly against the screw to prevent slipping and damaging the screw when tightening or loosening it.

Apply moderate force when tightening bolts and nuts to prevent stripping.

V. Wiring:

Special attention should be paid to avoid copper filings falling into important electrical devices during wiring operations, as this represents a significant hidden danger that cannot be easily detected.

VI. Installation of Devices in Electrical Control Boxes:

Incorrect direction of the cooling fan's airflow in and out of the control box can affect system stability due to the box's sealed nature and the need for heat dissipation from internal components through the cooling fan.

When installing components on the baseplate, use methods that allow for easy disassembly and maintenance, avoiding fastening methods that do not allow for removal from the front.