Troubleshooting Electrical/Electronic Systems

3rd ed., by Glen A. Mazur, Thomas E. Proctor

ELEC-200
Elec & Elect
Troubleshooting
Chapter-1
Troubleshooting

Dr. Talha Iqbal Associate Professor MCCC

 Troubleshooting Electrical/Electronic Systems 3rd ed.
Chapter 1: Troubleshooting

Objectives:
➢ Understand troubleshooting levels
➢ Getting familiar with troubleshooting methods
➢ Learn troubleshooting procedure
➢ Understand equipment reliability
➢ Get to know troubleshooter responsibilities
➢ Learning effects of electrical shocks
➢ Review electrical safety procedures

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Troubleshooting

Troubleshooting is the systematic elimination of the

various parts of a system or process to locate a
malfunctioning part.
A system is a combination of components, units, or
modules that are connected to perform a specific task.
A process is a sequence of operations that obtains desired
results.
A malfunction is the failure of a system, equipment, or
part to operate properly. To locate and correct a
malfunction quickly, troubleshooting is performed at
different levels.
Dr. Talha Iqbal Associate Professor MCCC
 Troubleshooting Electrical/Electronic Systems 3rd ed.
Chapter 1: Troubleshooting

➢ Troubleshooting Levels

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Troubleshooting Levels

The different levels

of troubleshooting:

Dr. Talha Iqbal Associate Professor MCCC

 Troubleshooting Electrical/Electronic Systems 3rd ed.
Chapter 1: Troubleshooting

✓ Troubleshooting Levels
➢ System Level

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Troubleshooting Levels – System Level

A system may include

▪ Programming terminals
▪ Controllers
▪ Operator terminals
▪ Displays
▪ Interfaces

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Troubleshooting Levels – System Level

▪ Troubleshooting at the system level requires knowledge of

the operation of the hardware, software, and interfaces in
the system.

▪ A systems analyst is an individual who troubleshoots at

the system level.

▪ A systems analyst observes each interface, connecting

cable, program, piece of equipment, and language used.

▪ System troubleshooting is performed on-site or off-site.

Dr. Talha Iqbal Associate Professor MCCC
 Chapter 1: Troubleshooting
Troubleshooting Levels – System Level

▪ On-site troubleshooting is performed at the location where the

hardware is installed.
▪ Off-site troubleshooting is done at a location other than where
the hardware is installed. An on-site computer sends information
about a malfunction to an off-site computer. The off-site computer
is programmed to solve malfunctions in systems. When the
malfunction is found, the off-site computer sends information to
the on-site computer.

Dr. Talha Iqbal Associate Professor MCCC

 Troubleshooting Electrical/Electronic Systems 3rd ed.
Chapter 1: Troubleshooting

✓ Troubleshooting Levels
✓ System Level
➢ Equipment/Unit Level

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Troubleshooting Levels – Equipment/Unit Level

▪ A unit is an individual component that performs a specific

task by itself.
▪ Systems are made when
units are connected.
▪ For example, a TV, Blu-
ray disc player, DVD/CD
player, and receiver
each are separate units.
When connected, an
entertainment system is
developed.
Dr. Talha Iqbal Associate Professor MCCC
 Chapter 1: Troubleshooting
Troubleshooting Levels – Equipment/Unit Level

▪ Unit level troubleshooting requires identification of the

faulty unit.
▪ When the malfunctioning unit is identified, substitution or
testing is performed.
▪ Substitution is the replacement of malfunctioning units. It
is performed when the unit is small, easily accessible,
replaceable, and a replacement is available.
▪ Testing is performed when the unit is a hard-wired unit or
is large in size, or when no replacement is available.
▪ Testing requires knowledge of use of test equipment and
the ability to correctly interpret the test results.
Dr. Talha Iqbal Associate Professor MCCC
 Chapter 1: Troubleshooting
Troubleshooting Levels – Equipment/Unit Level

▪ For example, if a main computer cannot operate a machine

connected to a programmable controller, a malfunction exists in the
main programming terminal, interface, connecting cables, or
programmable controller.
▪ A hand-held programming terminal is plugged into the
programmable controller to troubleshoot at the equipment/unit
level without disconnecting the equipment.
▪ If no information is being received from the
main computer, a malfunction exists
between the controller and the main
computer. If information is received, a
malfunction exists between the controller
and the machine.
Dr. Talha Iqbal Associate Professor MCCC
 Troubleshooting Electrical/Electronic Systems 3rd ed.
Chapter 1: Troubleshooting

✓ Troubleshooting Levels
✓ System Level
✓ Equipment/Unit Level
➢ Board/Module Level

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Troubleshooting Levels – Board/Module Level

▪ A board (module) is a group of electronic components

placed on a PCB (and an enclosure) that performs a set
task.
▪ Troubleshooting at the
board/module level requires finding
the faulty board/module.

▪ The board/module is then removed

and serviced or replaced.

Dr. Talha Iqbal Associate Professor MCCC

 Troubleshooting Electrical/Electronic Systems 3rd ed.
Chapter 1: Troubleshooting

✓ Troubleshooting Levels
✓ System Level
✓ Equipment/Unit Level
✓ Board/Module Level
➢ Component Level

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Troubleshooting Levels – Component Level

▪ A component is an individual device used in a board or module e.g.,

springs, resistors, diodes, transistors etc.
▪ Examples of faulty components include bad
transistors or capacitors inside a timer or
bad contacts or springs inside a magnetic
motor starter or pushbutton station.

▪ Troubleshooting at the component level is

time consuming. It is often economical to
replace an entire board or module.

▪ A voltmeter tests components or a group of

components on a board.
Dr. Talha Iqbal Associate Professor MCCC
 Troubleshooting Electrical/Electronic Systems 3rd ed.
Chapter 1: Troubleshooting

✓ Troubleshooting Levels
✓ System Level
✓ Equipment/Unit Level
✓ Board/Module Level
✓ Component Level
➢ Troubleshooting Methods

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Troubleshooting Methods

▪ Troubleshooting methods include by knowledge and

experience, by plant procedures, by manufacturer's
procedures, or a combination of these.
▪ Troubleshooting by knowledge and experience:
➢ learned from past malfunctions.
➢ temporarily effective because the primary fault is not
corrected.
➢ For example, a fuse may blow on a machine, stopping
production as a result. Changing fuses (or resetting
breakers) starts production, but the reason the fuse
blew is not clear.
Dr. Talha Iqbal Associate Professor MCCC
 Chapter 1: Troubleshooting
Troubleshooting Methods

▪ Troubleshooting by Plant Procedures:

➢ developed by supervisors or operators to ensure safe operation
➢ specific to the system/process used
➢ Example: defective module replacement on a programmable
controller

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Troubleshooting Methods

▪ Troubleshooting by Manufacturer’s Procedures:

➢ provided by the manufacturer
➢ shorter and more general than plant procedures
➢ Example: replacing the power supply on a programmable
controller

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Troubleshooting Methods - Flowcharts

▪ Procedures may be in the form of a diagram (called a flowchart) that

shows a logical sequence of steps for a given set of conditions.
▪ It helps a troubleshooter to follow a logical path when trying to
solve a problem.

▪ Flowcharts use symbols (ellipse, rectangle, diamond, and arrow) and

interconnecting lines to provide direction.
➢ An ellipse indicates the beginning and end of a flow chart or section of
a flow chart.
➢ A rectangle contains a set of instructions.
➢ A diamond contains a question stated so that a yes or no answer is
achieved. The yes or no answer determines the direction to follow
through the flow chart.
➢ An arrow indicates the direction to follow based on the answers.
Dr. Talha Iqbal Associate Professor MCCC
 Chapter 1: Troubleshooting
Troubleshooting Methods - Flowcharts

Dr. Talha Iqbal Associate Professor MCCC

 Troubleshooting Electrical/Electronic Systems 3rd ed.
Chapter 1: Troubleshooting

✓ Troubleshooting Levels
✓ System Level
✓ Equipment/Unit Level
✓ Board/Module Level
✓ Component Level
✓ Troubleshooting Methods
➢ Troubleshooting Procedure

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Troubleshooting Procedure

▪ A logical step-by-step process used to find a malfunction in a system

or process as quickly and easily as possible.
▪ Generally, it involves 5 steps:
➢ Obtain information: service manuals, prints, parts lists, local dealers,
training programs.
➢ Observe operation: carefully observe the operation during startup,
slow operation, fast operation and shutdown and look for problems.
➢ Isolate problems: Isolate the section that is probably malfunctioning
using observation. Look for potential secondary malfunction(s).
➢ Test faults: Use test equipment to test and check the components that
may be malfunctioning.
➢ Document Findings: Record faults found, and services performed. List
all findings. List components checked if a malfunction is not corrected.
List any suggestions to prevent the fault from recurring.
Dr. Talha Iqbal Associate Professor MCCC
 Chapter 1: Troubleshooting
Troubleshooting Procedure – Piping System Example
▪ A motor drives a pump that moves product through a piping system.
▪ The pump develops a higher-than-normal
pressure if the pipe that moves the product is
partially blocked.

▪ To develop the higher pressure, the motor

draws additional current.

▪ The additional current blows a fuse. The blown

fuse stops the motor.

▪ The primary malfunction is that the blown fuse

stopped the motor.
▪ The secondary malfunction is the scale buildup in the pipe.
▪ Changing the fuse solves the problem only until the fuse blows again.

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Troubleshooting Procedure – Piping System Example

▪ After changing fuses in a pump application, an

ammeter is used to test the current draw of the
motor.

▪ The motor is disconnected from the pump and

rechecked if the current draw is too high.

▪ There is a motor problem if the current is still

too high.

▪ There is a pump and/or piping system problem

if the current draw is normal.

Dr. Talha Iqbal Associate Professor MCCC

 Troubleshooting Electrical/Electronic Systems 3rd ed.
Chapter 1: Troubleshooting

✓ Troubleshooting Levels
✓ System Level
✓ Equipment/Unit Level
✓ Board/Module Level
✓ Component Level
✓ Troubleshooting Methods
✓ Troubleshooting Procedure
➢ Equipment Reliability

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Equipment Reliability

▪ One of most important factors in troubleshooting is the age of an

equipment.
▪ A typical life expectancy curve of an equipment is shown below.

Due to:
➢ Improper use
➢ Incorrect installation
✓ Voltage ➢ Worth repairing?
✓ Grounding ➢ Safe to operate?
✓ Environment

Dr. Talha Iqbal Associate Professor MCCC

 Troubleshooting Electrical/Electronic Systems 3rd ed.
Chapter 1: Troubleshooting

✓ Troubleshooting Levels
✓ System Level
✓ Equipment/Unit Level
✓ Board/Module Level
✓ Component Level
✓ Troubleshooting Methods
✓ Troubleshooting Procedure
✓ Equipment Reliability
➢ Troubleshooter Responsibilities
Dr. Talha Iqbal Associate Professor MCCC
 Chapter 1: Troubleshooting
Troubleshooter Responsibilities

▪ Trained personnel are required to troubleshoot and repair any

malfunctions.
▪ Part of the maintenance/service department of a company.
▪ The responsibilities include:
➢ Installing new equipment according to prints and codes
➢ Following a logical startup procedure for a new system
➢ Applying a preventive maintenance program
➢ Identifying malfunctions that occur
➢ Repairing faulty equipment
➢ Maintaining records of maintenance/conditions/downtime
➢ Handling emergencies
➢ Stay informed about the latest equipment/procedures/technologies

Dr. Talha Iqbal Associate Professor MCCC

 Troubleshooting Electrical/Electronic Systems 3rd ed.
Chapter 1: Troubleshooting

✓ Troubleshooting Levels ➢ Electrical Shock

✓ System Level
✓ Equipment/Unit Level
✓ Board/Module Level
✓ Component Level
✓ Troubleshooting Methods
✓ Troubleshooting Procedure
✓ Equipment Reliability
✓ Troubleshooter Responsibilities
Dr. Talha Iqbal Associate Professor MCCC
 Chapter 1: Troubleshooting
Electrical Shock

▪ According to the National Safety Council, over 1000 people

are killed each year in the US from electrical shock.
Electricity is the number one cause of fires.

▪ Main causes are improper wiring and misuse of electricity.

▪ The severity depends on amount, time, and path of

current, and condition and exposed area size of a body.

▪ Amount of current mainly depends on body resistance.

The lower the resistance, the greater the current flow.
Dr. Talha Iqbal Associate Professor MCCC
 Chapter 1: Troubleshooting
Electrical Shock

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Electrical Shock – Handling An Accident

▪ Break the circuit to free the person immediately and safely. Never
touch any part of a victim's body when in contact with the circuit. If
the circuit cannot be turned OFF, use any nonconducting device to
free the person. Resist the temptation to touch a person if the
power is not turned OFF.
▪ After the person is free from the circuit, send for help and
determine if the person is breathing. If there is no breathing or
pulse, start CPR. Always get medical attention for a victim of
electrical shock.
▪ If a person is breathing and has a pulse, check for burns and cuts.
Burns are caused by contact with the live circuit and are found at the
points that the electricity entered and exited the body. Treat the
entrance and exit burns as thermal burns and get medical help.
Dr. Talha Iqbal Associate Professor MCCC
 Troubleshooting Electrical/Electronic Systems 3rd ed.
Chapter 1: Troubleshooting

✓ Troubleshooting Levels ✓ Electrical Shock

✓ System Level ➢ Electrical Safety
✓ Equipment/Unit Level
✓ Board/Module Level
✓ Component Level
✓ Troubleshooting Methods
✓ Troubleshooting Procedure
✓ Equipment Reliability
✓ Troubleshooter Responsibilities
Dr. Talha Iqbal Associate Professor MCCC
 Chapter 1: Troubleshooting
Electrical Safety

▪ The use of PPE is required

whenever work may occur
on or near energized
exposed electrical circuits.
▪ It includes flame-resistant
clothing, head protection,
eye protection, ear
protection, hand and foot
protection, and rubber
insulated matting.

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Electrical Safety – General Rules

▪ Always comply with the NEC, OSHA, and NFPA-70E regulations.

▪ Use UL-approved appliances, components, and equipment.
▪ Ground any conductive component or element that does not have
to be energized.
▪ Turn OFF, lock out, and tag disconnect
switches when working.
▪ Use double-insulated power tools.
▪ Always use PPE.

▪ Never throw water on an electrical fire.

Turn OFF the power and use a Class C
rated fire extinguisher.

Dr. Talha Iqbal Associate Professor MCCC

 Chapter 1: Troubleshooting
Electrical Safety – General Rules

▪ When working in a dangerous area, work with another individual.

▪ Learn CPR and first aid.
▪ Do not work when tired or taking medicine that causes drowsiness.
▪ Do not work in poorly lit areas.
▪ Never bypass or disable fuses or circuit breakers.
▪ Always use nonconductive ladders. Never use a metal ladder when
working on or around electrical equipment.
▪ Use one hand when working on a live circuit to reduce the chance of
an electrical shock passing through the heart and lungs.
▪ When working on rotating machines e.g., a motor, ensure that
guards or housings are connected.

Dr. Talha Iqbal Associate Professor MCCC

 ✓ Troubleshooting Levels ✓ Electrical Shock
✓ System Level ✓ Electrical Safety
✓ Equipment/Unit Level
✓ Board/Module Level
✓ Component Level
✓ Troubleshooting Methods
✓ Troubleshooting Procedure
✓ Equipment Reliability
End of Lesson
✓ Troubleshooter Responsibilities
Dr. Talha Iqbal Associate Professor MCCC