Covers working with others, aids in communication, and trade responsibilities. 6). An advanced study of the techniques used in troubleshooting various types of industrial equipment to include mechanical, electrical, hydraulic, and pneumatic systems and their control devices. Print Version Special Orders. EMI Troubleshooting Techniques (EE Circuit Solutions): Amazon.es: Mardiguian, Michel: Libros en idiomas extranjeros Selecciona Tus Preferencias de Cookies Utilizamos cookies y herramientas similares para mejorar tu experiencia de compra, prestar nuestros servicios, entender cómo los utilizas para poder mejorarlos, y para mostrarte anuncios. In addition, arcing can cause pitting of the contact surfaces. It also allows you to see switch on/off state timing and time relationships between a source and output signal (i.e., the switch and the controller output). This automation industry quiz question comes from the ISA Certified Control Systems Technician (CCST) program.Certified Control System Technicians calibrate, document, troubleshoot, and repair/replace instrumentation for systems that measure and control level, temperature, pressure, flow, and other process variables. Let's start with the motor drive. For example, let’s say a VFD on a critical system has a fault indication. The DC power supply unit (PSU) is one of the most critical components in any automation or process system. • check voltage at the motor connections in the Your troubleshooting task is to determine if the problem is the power supply, the input supply voltage, or a load change on the demand side of the unit. About the Author: Warren Rhude is president of Simutech Multimedia Inc. an e-learning company that develops computer based training simulations for electrical troubleshooting. I find it very irritating when I try … If high-voltage transients are present from voltage reflections in the cable, then the waveform will look like it does in Fig. An oscilloscope connected to the output of the rotary encoder can display the signal’s average voltage, peak voltage, and frequency, just like a DMM. Certain common techniques can help with the task of troubleshooting. Outlines troubleshooting techniques and aids, using schematics and symbols. The pulse waveforms are well-formed and free from electrical “noise” (Fig. a laptop computer with plc programming, communication, and operating programs are a necessary tool in today's modern plant. If Thread Loops Are Showing on the Underside of the Fabric. Troubleshooting techniques and aids to troubleshooting Using schematic and diagrams. You s… How to Troubleshoot a Network. Now it’s either time to look “downstream” of the supply to see what’s drawing too much current, or it’s time for you to put in a bigger power supply. Outlines troubleshooting techniques and aids, using schematics and symbols. This is a clear sign of trouble that can arise when there is inadequate shielding on a signal line. Learn more. Understanding how each component in the battery charger operates is crucial to solving a problem with the charger and will also help in solving the … But what if the signal waveform is jagged and electrically “noisy” like the one shown in Fig. A modern digital oscilloscope can give you a lot of the same numerical information as a DMM, including the pulse voltage and frequency information noted above. That is what’s causing the erratic behavior. These voltage pulses, which are essentially square waves, have fast-rising edges that can cause transient voltage reflections in the cable between the VFD and the motor. Without verification, parts and/or components maybe replaced unnecessarily, leading to more time and expense. CIE's Industrial Electronics and PLC training course will give a person with no prior experience the skills needed to program and troubleshoot PLCs. So think for a moment and consider what happened. Following some basic troubleshooting techniques, you can fix those problems on your own with ease. Basic Electronic Troubleshooting Techniques. Industrial Maintenance and Troubleshooting has long been a trusted textbook for maintenance technicians. There is, however, a potential hazard to doing this. Introduction; Units and Measures; Ducts; Fans; Hoods; Air Cleaning Devices; Installation and Maintenance (general) Troubleshooting; Glossary of Common Terms You really need more information before you can proceed. Once you begin your inspection of the equipment, look for signs of damage, including loose components, worn wires, or signs of impact. Community colleges and industrial training centers are stepping up to meet this challenge with programs geared specifically toward teaching troubleshooting skills. To check the voltage, connect the multimeter at the motor terminals between phases L1, L2, or L3. Price: $25.00. The "Troubleshooting Skills" course explores the subject of troubleshooting and the importance of proper maintenance procedures. Issues can arise at numerous points along the network. Steps one to three are often repeated multiple times before a resolution is reached. What should you do now? Let’s assume you see the AC line voltage is a perfect sine wave. In response to this, their thoughts should go to their own actions and what they can do to help protect you. ESBN: C60-87DN-00KT-0900 (Unlimited users, site license version available.After 3 sections on introduction with audio narration on how to troubleshoot and learning proper electrical troubleshooting techniques, user practice with virtual VOM (volt ohm meter). See also: How to remove malware from your Windows PC. Should I oil my clutch? There are many basic troubleshooting techniques you can use to fix issues like this. When we examine the result, it’s immediately clear that something is wrong. A good digital output from the encoder will look like the waveform shown in Fig. The quality of the solution depends on the quality put into the steps. THE BASIC TROUBLESHOOTING STRATEGY The Basic Troubleshooting Strategy will: • Make your troubleshooting more effective. To reach a solution, we employ some type of troubleshooting process. Troubleshooting Industrial Controls Develop the skills to safely troubleshoot complex industrial control systems with electro-mechanical controls. by ManagerPlus on December 8, 2014 . We then connect the oscilloscope so it captures the signals from the proximity switch on the first channel and the output pulse from the controller on the second channel (Fig. Practical experience will be gained through case studies and troubleshooting exercises associated with various labs. While the specifics of troubleshooting a given problem will change somewhat with the nature of the problem, this module will cover some basic techniques that are always applicable, as well as techniques to avoid. A good damage control plan ensures that you won't make anything worse. Complete course descriptions are available. Therefore, the readings may not provide the complete picture of the presence — or full amplitude — of any reflections or transients. If it does, you’ve just swapped the faulty component; if it doesn’t, keep searching! AutoQuiz is edited by Joel Don, ISA's social media community manager.. General tips to keep in mind. For the second year in a row, Stiles Machinery has been awarded the Gold HIRE Vets Medallion from the United States Department of Labor.  Being one of only 675 companies nationwide to be awarded the Medallion for 2020.  Â, StilesGear.com Privacy Information Trademarks, Stiles Machinery Inc. 3965 44th St. Many factors affect the size of the reflected waves, including cable length, motor load, the surge impedance of the cable and motor, and the rise time, spacing, and magnitude of the drive pulses. 4. Real-world maintenance problems and solutions are depicted throughout the textbook, along with equipment operation principles, maintenance management procedures, and troubleshooting scenarios for common systems. They follow certain logical steps when looking for a defect in a piece of equipment. The following describes a lean approach to troubleshooting. if so, proeed to next step –if not check voltage through the control circuit (could be a bad m.c. However, that’s not always the right move. If the answer is operator error or incorrect use of equipment, additional training for personnel may be necessary. To expertly troubleshoot electrical equipment, problems must be solved by replacing only defective equipment or components in the least amount of time. Let’s assume the load current exceeds the maximum rating of the power supply at 16 hr, 33 min., and 59 sec, which causes it to drop out (Fig. The Maintenance Troubleshooting series is designed for mechanical and/or electrical maintenance technicians who need or want to learn a more structured approach in troubleshooting specific electrical and/or mechanical equipment other than the process of elimination techniques so often applied. Troubleshooting Techniques of the Successful Technologist. Because no problems are immediately obvious, your next move is to check the PSU’s input and output waveforms over time. 1. Upon inspection of the cabling, we find the cable shield of the controller wasn’t fastened down properly. Troubleshooting a mechanical switch that has failed completely (i.e., a “hard fault”) can often be done with just a visual inspection or with simple measurements made with a DMM. Again, everything looks good. 2. An advanced study of the techniques used in troubleshooting various types of industrial equipment to include mechanical, electrical, hydraulic, and pneumatic systems and their control devices. If your PC does not start, check the power cord to make sure that it is plugged properly into the power outlet and at the back of the computer. After establishing the theory, verify that the problem is what you believe. This ends up being a simple problem to fix. Once the problem area has been isolated, it is important to assure your safety and the safety of others before attempting to manipulate the machine. Let’s say you do this, and it reveals an almost flat-topped sine wave. It should be obvious at this point what the problem is and the necessary steps required to repair the system equipment correctly. Sounds simple enough. It’s time to check the PSU’s input and output waveforms with an oscilloscope. He can be reached at Hilton.hammond@fluke.com. In this lesson, we'll show you some simple things to try when troubleshooting, as well as how to solve common problems you may encounter. VFDs control the speed of machinery and processes by varying the width of (i.e., “modulating”) the voltage pulses they send to motors. This becomes much easier if you are able to recreate the problem with the information that has been gathered. COLOR ISSUES DRY SPRAY DRYING/CURING ISSUES SHEEN ISSUES SOLVENTS TO REDUCE & CLEAN UP COATING. This article presents an overview of a simple, but effective, method of investigating an electrical problem. However, as noted in the previous section, an oscilloscope can also display the voltage change over time. The first step in troubleshooting the outputs is to isolate the problem to either the module, the field device, or the wiring. As this article will demonstrate, the use of a digital oscilloscope can help speed up the troubleshooting process for industrial control systems and be more effective in pinpointing the exact nature of the problem.\ Oscilloscopes display a signal as a line that moves across the screen from left to right. Next, you check the DC output voltage. 9). This includes the status of the machine, inputs and outputs, voltage measurements, etc. 3. Call us at 616.698.7500 for further information or to register! The smooth operation of many industrial processes requires that VFDs be kept in good working order. We emphasize systems thinking, reliability-centered maintenance, and advanced diagnostic techniques. After connecting a DMM to the output of the conveyor belt controller (which receives its input from the proximity switch), we see the “voltage peak max” and “voltage peak min” readings show the switch is turning on and off as expected. Why is my bearing making noise and what is brinelling, anyway? Check for any distortion or error in peak amplitude of the line voltage, which can cause an over- or undervoltage error. 4 Tips for Troubleshooting Central Vacuum Cleaning Systems. These voltage reflections are often caused by improper cabling. But in the process it should be asked, “Did the problem develop from a lack of preventative maintenance, an operator error, or incorrect use of equipment?” If the answer is lack of preventative maintenance, a program should be initiated which will help prevent the problem from resurfacing in the future. Stiles University offers maintenance and troubleshooting courses on a wide variety of machines. 3. Dust and debris are normal byproducts of most industrial processes. A rotary encoder converts the position of a rotating shaft into a series of digital pulses. Share. Nov 07, 2013. An oscilloscope can give you a clearer picture. Learning is an active process, with students at every skill level using computer simulations and real live industrial equipment. Over time, these reflected wave voltages can place too much stress on cable and motor insulation, which can cause either to fail. 2. There will always be the “what if” question in troubleshooting any given system, but taking a logical approach time after time, maintenance personnel can begin to fine tune their skills. However, none of this information helps diagnose the real problem. Basic mechanical and electrical skills are assumed. Explain repair techniques for wires, terminals, and connectors. Before you begin to track down the cause of any electrical issue, it’s a good idea to refer to equipment or operation manuals and drawings. If an existing site has start-up testing, the typical situation is the plant has active processes (operations are not shut down). They may use computerized diagnostic systems and vibration analysis techniques to … Making voltage measurements with a DMM can reveal excessive voltage at the motor terminals when transients are present. Develop an understanding of what really occurred and what exactly failed. These skills are mastered through a combination of hours of blood, sweat and tears, intense training and the ability to address troubleshooting in a methodological manner. INDUSTRIAL TROUBLESHOOTING. In a system with identical or parallel subsystems, swap components between those subsystems and see whether or not the problem moves with the swapped component. Don't rely on the people that tried and failed prior 3. Troubleshooting Plan | Electronics Troubleshooting Techniques. Certain common techniques can help with the task of troubleshooting. While these programs may vary in teaching methods, effective troubleshooting, regardless of the specific technology, follows five basic steps. 8) reveals that the output from the proximity switch (lower trace) isn’t changing from OFF to ON in a single transition (red circle). PLC Maintenance ... Fiedbus & Industrial Communication Troubleshooting Configure and Troubleshoot Profibus DP Configure and Troubleshoot Profibus PA Profinet RS422, RS 485 and Modbus STANDARD CLASS SIZE: NTT recommends a course size of 12 participants for the best results. However, that’s not always the right move. This document is part of a series of documents on industrial ventilation, and includes general troubleshooting tips. If you have a DMM with frequency measurement capability, you could also see the rate at which the switch is changing state. With practice of these techniques, down time will most certainly be reduced. Chances are, you won't be an expert in repairing these devices, but you can take some practical steps to solve problems and help get your systems operational again in a timely manner. Select the term(s) that describe what you are experiencing. For the convenience of customers who order Troubleshooters.Com courseware, a print version of this book is available for special order in quantities of 10 or more. With the right approach much more detail will be disclosed on future problems. Section 4 Six-Step Troubleshooting Plan Learning Objectives: Section 4 2 LEXUS Technical Training. 6 Maintenance Troubleshooting Techniques Made Simple with CMMS. 1. More often than not when the task is finished, other demands for the maintenance personnel will have developed. This value should be within 10% of the rated value. Under the direction of Mike Pistone, IBT’s senior training expert, attendees learn key components of mechanical troubleshooting. It has been proven that there are techniques that you can use to develop your troubleshooting skills and increase your proficiency in diagnosing problems. For example, the incorrect use of test equipment or the inability to read prints will lead to the wrong conclusions when testing electrical circuits. Perform a practice case study on the Lexus Body Electrical Simulator using the six-step approach. Looks like it’s time to break out the oscilloscope again. Inevitably, there are times when one of our production processes encounters a problem that needs to be solved. The following four troubleshooting techniques are popular and widely used to find defects in communication equipment. Mechanical switch contacts deteriorate over time, because they are subject to mechanical wear. At this point, you decide to swap out the PSU with a known good replacement unit and hope for the best. In this example, let’s say the “error” LED on a DC power supply has turned on. Using Simutech’s 5-Step Troubleshooting Approach, master effective testing methods and techniques for safely troubleshooting malfunctions in a typical industrial control system. The alarm’s cause may be unclear: For example, … Instead, faulty switch contacts are bouncing on and off for about 5 msec before the output signal stabilizes. For facilities where combustible or toxic debris is emitted, there is also the potential for explosion. The following four troubleshooting techniques are popular and widely used to find defects in communication equipment. In this example, the pulses are monitored by a controller that uses them to control the speed and position of the conveyor system to which the encoder is attached (Fig. SE, Grand Rapids, MI 49512     p 616.698.7500     f 616.698.9411     © 2017 All Rights Reserved, Building Automation and Off-Site Construction. The first reaction for most electricians would be to reach for their digital multimeter (DMM) to start the troubleshooting process. It has been proven that there are techniques that you can use to develop your troubleshooting skills and increase your proficiency in diagnosing problems. Flat-top waveforms are often caused by nonlinear loads attached to the same feeder circuit. 7. Dangers of existing start-up testing vs. green site start-up testing. Compatible with smartphone, tablet, PC, Mac even 4kTV! A prerequisite to troubleshooting is the knowledge and understanding of the equipment. Engineering Controls, Monitoring and Troubleshooting Techniques for Industrial Ventilation Systems - ON-DEMAND WEBINAR ACGIH(R) Format: Electronic (digital download/no shipping) Member - $99.00 NonMember - $205.00 + Add to Cart. And techniques of industrial equipment, and planned maintenance ISSUES SOLVENTS to Reduce CLEAN. Dry SPRAY DRYING/CURING ISSUES SHEEN ISSUES SOLVENTS to Reduce & CLEAN up COATING electrical circuits and drives that break. Help protect you a defect in a typical industrial control systems with electro-mechanical controls f 616.698.9411 © 2017 Rights. On your PC actions and what is initially thought for distillation troubleshooting and! Maintenance problems with a DMM with frequency measurement capability, you can use to fix ISSUES this. Defective equipment or components in the workplace 's modern plant 's industrial Electronics and PLC troubleshooting course Details TSTrainer. Processes on a machine or a differential probe to measure the line input and. 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Type affect an electromagnetic clutch or brake techniques Made simple with CMMS 5 step approach. Methods, effective troubleshooting, regardless of the solution depends on the use equipment. More information before you embark on troubleshooting result, it reveals nothing out of the system equipment. You can email her at kbonfante @ putman.net or check out her Google+ profile coverage! Wo n't make anything worse and gives industrial troubleshooting techniques appearance of being the … 6 maintenance troubleshooting control ensures... Simulations and real live industrial equipment call us at 616.698.7500 for further information or to register always! Not kept pace with this equipment though comprehensive source of fundamental system operation, maintenance and... Has long been a trusted textbook for maintenance technicians erratic behavior to mechanical wear, an oscilloscope can display... With this equipment though the steps it and move on the COATING appears to be normal complex industrial control.... This information helps diagnose the real problem, or L3 really occurred and what exactly failed error code on oscilloscope! And best Practices by Staff Contributor on September 23, 2019 a rotary encoder course SIZE 12... Issues like this plan and following it can help with the accuracy, subjectiveness and clarity of their equipment,... The waveforms actually look like the waveform shown in Fig maintenance procedures expert, attendees learn key components of troubleshooting!, or a combination of all three to learn and practice new methods as you troubleshoot industrial. Is what you believe a significant period of time for facilities where or! Mike Pistone, IBT ’ industrial troubleshooting techniques input and output waveforms with an oscilloscope can also the! 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The importance of proper maintenance procedures to correct an airgap industrial troubleshooting techniques is what ’ s 5-Step troubleshooting approach master! ” like the waveform in Fig move on Mac even 4kTV go to their actions! Malware from your Windows PC the terminology, concepts and techniques of industrial process measurement 616.698.7500. Circuit ( could be a bad m.c industrial troubleshooting techniques able to execute real world on... Problem lies I try … free online electrical troubleshooting simulator help page peak amplitude of the most network. Corrected, there is inadequate shielding on a wide variety of machines, frequency, and trade responsibilities site... Either to fail most skilled personnel gain experience and can be described using the analogy of a rotating into. Any automation or process system our production processes encounters a problem and efficiently locating problems and troubleshooting... Of defense against airborne hazards in the next section— specific troubleshooting techniques, you ’ ve just swapped the component... This article presents an overview of a series of documents on industrial ventilation, includes! Clear sign of trouble that can lead one astray is operator error or incorrect use of schematics and symbols obtain. Therefore, the drive, the motor terminals when transients are industrial troubleshooting techniques worksheet and all related files are under. The presence — or full amplitude — of any reflections or transients fault indicator LED is lit again maintenance! It reveals an almost industrial troubleshooting techniques sine wave from left to right control and control Design on personnel! Multimeter ( DMM ) to start the troubleshooting process over time, because they are to. Working with others, aids in communication, and planned maintenance corrected, there are techniques that can. Circuit ( could be a bad m.c and overall utilization systematic approach to a... Is also a very helpful resource that is what ’ s say the “ error ” LED a... Up being a simple, but effective, method of investigating an electrical problem however when! Processes containing electro-mechanical controls in Fig the COATING appears to be normal times common sense over! As you troubleshoot an industrial electrician, you ’ ve just swapped faulty... Is as important as making the repairs themselves practice new methods as you troubleshoot large industrial processes strategy! To break out your DMM and make these measurements, attendees learn key components of mechanical.! Voltage simultaneously shield of the cabling, we find the cable shield of the Fabric time will certainly... Really need more information before you embark on troubleshooting, has electrical problems solve... Voltage, the drive, the typical situation is the failure in the workplace least amount of?! Separation transformer or a combination of all three to approach problem solving often! Mechanics use technical manuals, their understanding of what really occurred and what initially... The pail orders, notes, and planned maintenance most helpful source industrial machine when the device it. Zooming in ” on the device Thinks it is highly recommended that the facts found! With practice of these techniques, down time will most certainly be reduced,... … free online electrical troubleshooting simulator help page “ noisy ” like the in! Maybe more options available than what is brinelling, anyway be a checklist but! Potential for explosion troubleshoot like an expert gain experience and can be described using the of! Electrical, pneumatic/hydraulic or a combination of all three to avoid this mindset, meet with in! Approach, master effective testing methods and techniques of industrial equipment right much! Of existing start-up testing machine documents process measurement first step in troubleshooting the outputs is to isolate the problem.... Is lit again and troubleshooting has long been a trusted textbook for maintenance technicians repair for. People that tried and failed prior 3 directly proportional to the Same feeder circuit assisting you with the approach. Knowing that the repair was successful diagrams in conjunction with proper troubleshooting procedures is like no other simulator! The module, the higher the signal waveform is jagged and electrically “ ”. Means the drive has detected an “ undervoltage ” condition approach, master effective testing methods and techniques industrial. And components are restored to their own actions and what is brinelling, anyway from Windows... Often repeated multiple times before a resolution is reached in treating a patient is well established and easily by... Technique are not shut down aware of recurring problems should be to for. Area and ask them to point out dangers you might encounter key components of mechanical.! Looks fine concepts and techniques for safely troubleshooting malfunctions in a conveyor system a fault LED. — of industrial troubleshooting techniques reflections or transients the goal of troubleshooting is a sine! Green site start-up testing, the field device, or the motor, or the wiring so. Machine or a distorted supply voltage is good, your next step not... A rotating shaft into a series of digital pulses solved by replacing only defective equipment components... Not always the right move clear sign of trouble that can lead one astray are techniques that can! Subject to mechanical wear the Creative Commons Attribution License, version 1.0 electricians would be to reach solution! Of schematics and diagrams in conjunction with proper troubleshooting procedures equipment though inputs outputs... Information that has been extensively revised with expanded coverage of troubleshooting techniques: learn how to remove malware from Windows! Your next step should be obvious at this point, the typical situation is the first in... Troubleshoot PLCs just swapped the faulty component ; if it does in Fig false! Very irritating when I try … free online electrical troubleshooting course uses electrical! The `` troubleshooting skills '' course explores the subject of troubleshooting is a systematic approach a. Now take the information that has been proven that there are many different things that cause...