Never seen anything like that. Only suggestion is to keep working backwards. Is it  possible to temporarily feed the machine from another source?

Hypertough battery leaking is one concern and battery fires are another topic worth mentioning.

Hyper Tough batteries, like any batteries, can potentially catch fire under certain conditions, although such incidents are rare. Battery fires are generally caused by specific factors that lead to overheating or short circuits. Here are some common causes and preventive measures:

Common Causes of Battery Fires:
Overcharging: Charging batteries beyond their recommended capacity can cause them to overheat, leading to a risk of fire.

Short Circuits: A short circuit occurs when the battery terminals come into direct contact with each other or with conductive materials, causing excessive current flow and heat buildup.

Physical Damage: Dropping, puncturing, or otherwise damaging a battery can compromise its internal structure, leading to thermal runaway and fire.

Manufacturing Defects: Poor quality control during the manufacturing process can result in defects that may cause batteries to overheat and catch fire.

Improper Storage: Storing batteries in high temperatures or in direct sunlight can increase the risk of overheating and fire.

Use of Incorrect Charger: Using a charger that is not compatible with the battery can lead to improper charging and overheating.

The risk of Hyper Tough batteries catching fire is low, but it is important to follow proper usage, charging, and storage guidelines to minimize this risk. Any cheap battery can detonate or burst into flames under the right conditions if you ask me.
 

What are the odds that Hypertough batteries will leak?

Hyper Tough batteries, like any batteries, have the potential to leak under certain conditions. Battery leakage can occur due to a variety of factors, including manufacturing defects, improper usage, or poor storage conditions. Here are some common reasons why batteries might leak and tips to prevent it:

Poor quality control during manufacturing can result in defects that may cause batteries to leak. Repeatedly using or charging batteries beyond their recommended capacity can cause them to overheat and leak. Dropping or otherwise damaging the battery can compromise its casing, leading to leakage. Extreme temperatures (both high and low) can cause batteries to swell and leak. Humidity and exposure to moisture can also be a factor. Batteries that are old or past their expiration date are more likely to leak due to degradation of internal components. Storing batteries in places with extreme temperatures or high humidity can increase the likelihood of leakage. This hold true for the Hypertough batteries and basically most other brands.

G4D16R Troubleshooting and Fault Finding

Check Connections:

Ensure all wiring connections are secure and correctly installed according to the module's wiring diagram.

Verify that input devices (e.g., switches, sensors) are properly connected and functioning.

Inspect Input Devices: Test input devices independently to ensure they are working correctly and providing the expected signals.

Replace any faulty input devices.

Monitor Signal Quality: Use an oscilloscope or multimeter to check the quality and consistency of the input signals.

Ensure that the input signals are within the voltage and current specifications for the G4D16R.

Test Module Functionality: Swap the G4D16R module with a known working module to determine if the issue is with the module or another part of the system.
Test the module in a different slot or rack to rule out issues with the backplane or slot.

Check for Electrical Noise: Ensure that the system is properly grounded and shielded to minimize electrical noise and interference.

Use ferrite beads or other noise suppression techniques on input lines if necessary.

Review Firmware and Software: Ensure that the control system's firmware and software are up to date and compatible with the G4D16R module.

Check for any known issues or updates from Opto 22 that might address the problem.

Contact Support: If troubleshooting steps do not resolve the issue, contact Opto 22 technical support for assistance. They can provide guidance and help diagnose more complex problems. You should really be able to sort this out on t your own however if you follow basic troubleshooting steps.

Is anyone still counting on the G4D16R components and systems? They have been reliable for me.

The Opto G4D16R is a digital input module designed for use in industrial automation and control systems. It is part of the G4 series from Opto 22, a company known for manufacturing reliable and high-performance industrial automation, control, and monitoring products.

Digital Input Module:

The G4D16R is specifically designed to handle digital inputs, which are typically signals from switches, sensors, and other devices that provide a binary (on/off) signal.

There are 16 Channels:

The module features 16 input channels, allowing it to monitor and report the status of 16 separate digital input signals.

Critical Opto-Isolation:

Each input channel is optically isolated to protect the module and the rest of the control system from electrical interference and surges, ensuring reliable operation in industrial environments.

Control and Monitor Compatibility:

The G4D16R is designed to work with Opto 22's modular I/O systems, including the G4 I/O racks, which are used to build flexible and scalable automation solutions.

Very Useful LED Indicators:

The module typically includes LED indicators for each input channel, providing visual feedback on the status of each input (whether it is on or off).

Analog and Digital Input Types:

It can handle a variety of input signal types, including dry contact closures and DC voltage inputs, making it versatile for different applications.

Why would you still want to use OPTO 22 G4D components?

Industrial Automation: Used in factories and manufacturing plants for monitoring and controlling machinery and processes.

Building Automation: Used in smart building systems for monitoring switches, sensors, and other control devices.

Energy Management: Used in energy monitoring and management systems to track the status of various electrical components.

Infrastructure Monitoring: Used in systems that monitor critical infrastructure such as water treatment plants, power grids, and transportation systems.

The Opto G4D16R is a robust and versatile digital input module suited for a wide range of industrial and commercial applications. Its ability to handle multiple input signals with opto-isolation and compatibility with Opto 22's modular systems makes it a valuable component for automation and control solutions.

They still have occasional problems, but nothing to be too concerned with. While the Opto 22 G4D16R digital input module is generally reliable, issues can arise related to input signals, LED indicators, opto-isolation, communication, and installation. Systematic troubleshooting, including checking connections, input devices, signal quality, and potential electrical noise, can help identify and resolve many common problems.

No Input Detection: The module might not detect input signals correctly.
Intermittent Signals: Input signals might be detected intermittently or inconsistently.

Non-Functioning LEDs: The LED indicators for input channels might not light up as expected, even when there is an input signal.

Incorrect LED Status: LEDs might show incorrect statuses, such as staying on when there is no input signal or vice versa.

Electrical Noise: The module might not effectively isolate electrical noise, leading to signal interference or false readings.

Component Damage: The opto-isolation components can be damaged by electrical surges, affecting module performance.

Cranes are a major safety concern, if I were you I'd just look towards upgrades and replacements when crane parts become obsolete

Are the cheap Pittsburg tools any good? Anybody have anything good to say about these? The general idea is that they're too cheap to be any good.

I think this part of the forum is not going to take off. Ebay has a lock on this end of things.

Anybody else collect vintage meter movements? There's some cool stuff out there.

I have a range of unused machine parts that are still in their original packaging and ready to be put to use. These parts are manufactured by reputable companies and are of the highest quality, ensuring that they will provide reliable and efficient performance in your machines.

Whether you need replacement parts for your CNC machine, industrial robot, or other machinery, I have a variety of options available. And since these parts are unused and still in their original packaging, you can be sure that they are in pristine condition and ready to be installed.

Don't pay full price for machine parts when you can get the same high-quality products at a discounted price. Contact me today to learn more about the unused machine parts I have for sale and how they can help keep your machines running smoothly and efficiently!

It's hard to start listing individual part numbers though, that's what stops me from posting. Seems like a longshot that people are going to want small specific parts. Big ticket items would work out better for this forum.

GearWrench is a brand of hand tools known for its high-quality products and innovative designs. The brand is highly regarded by mechanics and DIY enthusiasts alike, and its products are widely used in the automotive, aerospace, and industrial sectors.

Many people consider GearWrench tools to be of high quality and not cheesy. They are made from durable materials and designed to withstand heavy use, and they come with a lifetime warranty against defects in materials and workmanship. Additionally, GearWrench offers a wide range of tools, from sockets and ratchets to wrenches and pliers, so users can find the right tool for their specific needs.

Overall, GearWrench is a reputable brand with a strong reputation for producing high-quality hand tools that are reliable and durable.

regardless of where they're made, I think they are pretty solid tools.

This is an old post now but the problem was just that, loose wires inside of a wire-nut which shouldn't have been there in the first place

Thanks, I have had some ghost problems in the recent past and I attempted to install line reactor kits thinking I was onto something, I didn't see a definitive difference for my issue in this case

Possibly called a safety band, these are pretty much obsolete, everything has gone laser and infrared now

I know this is an old post but I can tell you with no uncertainty that electrical noise is common with electrically actuated air valves because of inductive feedback.

What is inductive feedback?

Inductive feedback is generated by the tiny oscillation of mechanical spring and parts within the valve that come with the movement of the mechanical valve parts at a high speed.

A snubber or filter will definitely help when you have this problem.

What is Sensorless Vector Control? Is sensorless control somehow superior to other methods, or is it just another option based on application?

Please define reverse torque seems like common sense torque in reverse but am I missing something?

What is NEMA exactly and how much do NEMA ratings matter in a standard industrial environment?

Is it common practice to use an isolation transformer on a drive or inverter in noisy environments? Or do we only add isolation transformers when there are problems?

Dynamic braking seems to be the braking solution for most applications in my opinion. Is there a situation or certain type of application where you don't use dynamic braking?

Can someone provide a textbook definition of deadband in relation to inverters and drives? What is deadband?

Question: What is reactance in regards to drives and motors? What does "reactance" mean?

Question:  What is Duty Cycle in reference to AC and DC motors?

Question:  What is Break Away Torque? I believe it is a motor spec but not sure how to define it.

Thank You!

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