| Equipment can malfunction for a variety of | | | | several approaches that troubleshooters use. |
| reasons. Mechanical contacts and parts can wear | | | | They may have different steps or processes but |
| out; wires can overheat and burn open or short | | | | they have the following in common: They all |
| out; parts can be damaged by impact or abrasion; | | | | approach problems systematically and logically |
| etc. Equipment may operate in a manner far | | | | thus minimizing the steps and ruling out trial and |
| different than it was designed to, or not at all. | | | | error. One such approach used to teach |
| Typically, when equipment fails there is a sense of | | | | troubleshooting is called the '5 Step Approach'. A |
| urgency to get it fixed and working again. If the | | | | summary of the key steps are: |
| defective equipment is part of an assembly line, | | | | 3. - Observe Most faults provide clues as to their |
| the whole assembly line could be down causing | | | | cause. There could be visual clues such as signs of |
| unexpected 'time off' and lost revenue. If you are | | | | damage or improper operation. Don't forget to |
| at a customer site to repair equipment, the | | | | use your other senses; sounds and smells can |
| customer may watch you, knowing that they are | | | | also provide valuable clues. Through careful |
| paying for every minute you spend | | | | observation and a some reasoning, most faults |
| troubleshooting and repairing their equipment. | | | | can be identified to the actual component with |
| Either one of these scenarios - and there are | | | | very little testing. |
| more, can put a lot of pressure on you to solve | | | | 4. - Define Problem Area At this stage you apply |
| the problem quickly. | | | | logic and reasoning to your observations to |
| So What is troubleshooting? It is the process of | | | | determine the problem area of the malfunctioning |
| analyzing the behavior or operation of a faulty | | | | equipment. |
| circuit to determine what is wrong with the circuit. | | | | 5. - Identify Possible Causes Once you have the |
| It then involves identifying the defective | | | | problem area(s) defined it is necessary to identify |
| component(s) and repairing the circuit. Depending | | | | all the possible causes of the malfunction. |
| on the type of equipment, troubleshooting can be | | | | 6. - Determine Most Probable Cause Once the list |
| a very challenging task. Sometimes problems are | | | | of possible causes has been made it is necessary |
| easily diagnosed and the problem component | | | | to prioritize the items as to the possibility of them |
| easily visible. Other times the symptoms as well | | | | being the actual cause of the malfunction. |
| as the faulty component can be difficult to | | | | 7. - Test and Repair Once you have determined |
| diagnose. A defective relay with visual signs of | | | | the most probable cause, you must test it to |
| burning should be easy to spot, whereas an | | | | prove it to be the problem or not. |
| intermittent problem caused by a high resistance | | | | See A Systematic Approach to Troubleshooting |
| connection can be much more difficult to find. | | | | for more details on this approach. |
| What makes an expert Troubleshooter? One trait | | | | 8. Understand how to use tools such as prints, |
| of expert troubleshooters is that they are able to | | | | diagrams and test instruments to identify |
| find virtually any fault in a reasonable amount of | | | | defective components. Let's first look at prints |
| time. Easy faults, complicated faults, they find | | | | and diagrams. Some of the key things you should |
| them all. Another trait is that they typically replace | | | | be able to determine from these are: |
| only the components that are defective. They | | | | 9. - how the circuit should operate |
| seem to have a knack for finding out exactly | | | | 10. - what kind of features the circuit has |
| what is wrong. No trial and error here. So what is | | | | 11. - what voltages you should expect at various |
| their secret? | | | | points on the circuit |
| You might think that a person who has a very | | | | 12. - where components are physically located |
| good understanding of how the equipment works, | | | | 13. - how the components are actually wired |
| should be able to troubleshoot it effectively. Being | | | | together Various types of test instruments are |
| a good at troubleshooting requires more than this. | | | | available for testing electrical circuits. The ones |
| Expert troubleshooters have a good | | | | you choose depends on the type of circuit and its |
| understanding of the operation of electrical | | | | components. A common test instrument which is |
| components that are used in circuits they are | | | | invaluable to a troubleshooter is a Multimeter. It is |
| familiar with, and even ones they are not. They | | | | capable of measuring voltage and resistance with |
| use a system or approach that allows them to | | | | some meters capable of other measurements |
| logically and systematically analyze a circuit and | | | | such as current and capacitance. You must be |
| determine exactly what is wrong. They also | | | | able to determine what type of test instrument |
| understand and effectively use tools such as | | | | to use, when and where to use it, and how to |
| prints, diagrams and test instruments to identify | | | | safely take readings with it. |
| defective components. Finally, they have had the | | | | 14. Practice! Troubleshooting, like any skill, requires |
| opportunity to develop and refine their | | | | practice to become proficient. Practice can be |
| troubleshooting skills. | | | | difficult to get. Depending on your job, you may |
| If you want to troubleshoot like the pros you will | | | | not have the opportunity for enough |
| need to develop your skills in each of these areas. | | | | troubleshooting practice. And even if you do, your |
| Let's look at them in more detail. | | | | employer may not want you to practice |
| | | | troubleshooting on equipment they depend on. |
| 1. Understand how the circuit works. This consists | | | | Until you become reasonably competent, it is best |
| of understanding the operation of all the | | | | to practice troubleshooting in a controlled |
| components that are used in the circuit. This could | | | | environment. One option is to build or purchase |
| include such components as: push buttons, | | | | equipment that can be used for troubleshooting. |
| contactors, various types of switches, relays, | | | | This equipment is designed with the ability to |
| sensors, motors, etc. Electrical circuits typically | | | | apply faults to it. Here you can practice your skills |
| control or operate mechanical systems and | | | | in a very realistic environment without affecting |
| components. You also need to understand how | | | | equipment in use. Another option which is gaining |
| these mechanical aspects of the equipment | | | | more popularity is the use of computer |
| operate to carry out the work. You need to be | | | | simulations. These simulations can be extremely |
| able to determine how the circuit works under | | | | realistic and allow you to practice your |
| normal conditions and what effect changing one | | | | troubleshooting skills in a safe environment. Some |
| of the circuit inputs has on the circuit operation. | | | | other advantages are portability, cost |
| For example, what happens to the overall circuit | | | | effectiveness, and can be used in almost any |
| operation when a push button is pressed; which | | | | location. Some even include an assessment |
| relays energize, which lights illuminate, does the | | | | function that assesses the user's troubleshooting |
| pump start or stop, etc. You also need to be able | | | | skill, provides feedback, and records their |
| to determine what effect a faulty component | | | | troubleshooting processes. Review your own skills |
| may have on the circuit operation. | | | | in each of these areas. Improving any one of |
| 2. Use a logical, systematic approach to analyze | | | | them, along with a good dose of practice, will |
| the circuit's behavior. This is critical. There are | | | | improve your troubleshooting skills. |