Professional Documents
Culture Documents
Technical Guidlines For Instrumentation Repairs PDF
Technical Guidlines For Instrumentation Repairs PDF
PRACTICAL MANUAL
ON
INSTRUMENTATION
MAINTENANCE AND REPAIRS
1|Page
TABLE OF CONTENT
SECTION 1
INTRODUCTION
1.1 Aims of Practical Work
1.2 Format for Laboratory Report Writing
SECTION 2
Practical 1: Safety and Maintenance Rules in Instrumentation Workshop
Practical 2: Basic Tools, Instrumentation, and Equipment Identification
Practical 3: Basic Troubleshooting Tips
Practical 4: Transistor circuit test and fault finding using a multimeter
Practical 5: Testing Diodes and Transistors
Practical 6: Troubleshooting tips: Automation and process control loops
2|Page
SECTION 1
INTRODUCTION
Practical work is one of the prerequisite for excelling in a course in the
engineering field. The importance of practical in engineering fields can never
be over emphasized. It is one of the most effective teaching methods
necessary to develop craft skills or for the conduct of laboratory
experiments. A student may have an over view of an entire system but
through laboratory experiment individual components of the system can be
investigated and then assembled to produce a complete picture.
3|Page
Practical 1
Topic: Safety and Maintenance Rules in Instrumentation Workshop
Aim: To identify safety rules and getting used to them
Discussion:
1. All personnel that will use the machine tools must either take a class in
Machine Tool Operation or, through their prior experience, be able to
prove their proficiency to CEE Machine Shop Supervisor.
2. All shop users must wear eye protection while working with hazardous
machine tools and power tools.
3. Hearing protection (ear plugs) should be readily available to workshop
users.
4. A first aid kit must be placed in the workshop, and a lab member should
be assigned to keep it well stocked.
5. A fire extinguisher must be readily available.
6. Basic Safety rules must be followed at all times. Among these are:
Long hair must be tied back at all times.
No flip-flops while working with hazardous machine tools and power
tools;
Any oil spilled on the floor must be immediately cleaned up.
Loose fitting clothing must be tucked in or tied up.
Neckties must be removed.
Bracelets and other loose jewelry must be removed prior to using the
shop.
No horseplay around the machines is permitted. Machine tools can be
dangerous.
7. No person should work alone. At least two people should be in the
workshop. A buddy system may be used. The buddy, however, must be in
the building while the shop user is in the shop. The buddy is responsible
for checking every 15 minutes to see that the workshop user is safe at all
4|Page
times. The workshop user must put his/her buddy’s name and location in
the logbook.
8. The workshop area must be kept clean. It is impossible to maintain a safe
work environment if tools, stock and last week’s pure water sachet are
lying about the equipment. A lab member should be put in charge of
workshop cleanliness.
9. Practice common sense. If your gut tells you not to setup a part in a
certain way in a machine, don’t do it. Most workshop accidents are a
result of lack of knowledge, not carelessness. If you have any doubt,
consult personnel working in the Student Instrumentation Workshop.
Electrical shock hazard from TV, computer and other video monitors,
microwave ovens, the switchmode power supplies in some VCRs and
computer peripherals, electronic flash units, some parts of audio
equipment, hand and stationary power tools, large appliances, and
even many small line powered appliances.
Mechanical hazards from the moving parts of various appliances,
computer peripherals, hand and stationary power tools, and especially
gasoline powered yard equipment.
Risk of CRT implosion from equipment using large CRTs.
Vision hazards from the lasers in CD players and CDROM drives, DVD
players and DVDROM drives, other optical data storage devices, and
laser disc players.
5|Page
See the SAFETY sections of the documents dealing with your equipment for
additional safety information for your equipment.
Questions
1. Mention and briefly explain 5 Safety and Maintenance Rules in
Instrumentation Workshop.
6|Page
Practical 2
Topic: Basic Tools, Instrumentation, and Equipment Identification
Aim: At the end of the session, the student should be able to identify the
basic instrumentation Equipment
Discussion:
Hand tools: A good set of hand tools includes an assortment of wrenches,
screwdrivers, pliers, wire cutters, wire strippers, channel locks, punches,
hammers and other common hand tools.
Screw Drivers: A set of small screw drivers with different blade styles and
sizes can be useful for working on control system components for calibration
and other adjustments as well as working with small terminal strips.
Safety Equipment: Hard hats, safety glasses, ear protectors, and steel-toe
shoes are generally good ideas on construction sites and around machinery
and may be mandatory at some locations.
7|Page
Thermometer: is a device that measures temperature or temperature
gradient using a variety of different principles. A thermometer has two
important elements: the temperature sensor (e.g. the bulb on a mercury-in-
glass thermometer) in which some physical change occurs with temperature,
plus some means of converting this physical change into a numerical value
(e.g. the visible scale that is marked on a mercury-in-glass thermometer).
8|Page
However, a larger, higher precision meter can be useful for cross checking
calibration and input signals on control systems.
10 | P a g e
Dataloggers: Even though most current technology buildings are equipped
with DDC systems that allow trending of the data required to commission
the system, having several data loggers available with a variety of input
sensors to supplement this capability can often be useful for the following
reasons:
11 | P a g e
Shortridge or Other Electronic Air Data Multimeter: An electronic
pressure measurement meter like the meters used by most balancing firms
is an expensive but highly useful tool. Most meters of this type can measure
pressures in the thousandths of an inch water column range accurately, and
thus can detect and measure low velocity pressures and air flow rates.
12 | P a g e
Electronic Hygrometer and Electronic Pressure Gauge
13 | P a g e
Although function generators cover both audio and RF frequencies, they are
usually not suitable for applications that need low distortion or stable
frequency signals. When those traits are required, other signal generators
would be more appropriate. Some function generators can be phase-locked
to an external signal source (which may be a frequency reference) or
another function generator. Function generators are used in the
development, test and repair of electronic equipment. For example, they
may be used as a signal source to test amplifiers or to introduce an error
signal into a control loop.
14 | P a g e
different frequencies may be obtained. Sawtooth waves can be produced by
charging the capacitor slowly, using a current, but using a diode over the
current source to discharge quickly - the polarity of the diode changes the
polarity of the resulting sawtooth, i.e. slow rise and fast fall, or fast rise and
slow fall.
A 50% duty cycle square wave is easily obtained by noting whether the
capacitor is being charged or discharged, which is reflected in the current
switching comparator output. Other duty cycles (theoretically from 0% to
100%) can be obtained by using a comparator and the sawtooth or triangle
signal. Most function generators also contain a non-linear diode shaping
circuit that can convert the triangle wave into a reasonably accurate sine
wave by rounding off the corners of the triangle wave in a process similar to
clipping in audio systems.
15 | P a g e
Procedure:
Identify the various instrumentation Equipments in the laboratory
Question:
Write briefly on 10 instrumentation equipments found in the laboratory
stating their functions.
16 | P a g e
PRACTICAL 3
Topic: Basic Troubleshooting Tips
Aim: To understand the basic troubleshooting tips
Discussion:
Some of the Rules of Troubleshooting
1. Safety first - know the hazards associated with the equipment you are
troubleshooting. Take all safety precautions. Expect the unexpected. Take
your time.
2. Always think 'what if'. This applies both to the analytic procedures as well
as to precautions with respect to probing the equipment.
3. Learn from your mistakes. We all make mistakes - some of them can be
quite costly. A simple problem can turn into an expensive one due to a
slip of the probe or being over eager to try something before thinking it
through. While stating that your experience in these endeavors is
measured by the number of scars you have may be stretching the point,
expect to screwup - we all can point to that disaster due to inexperience
or carelessness. Just make it a point not to make the same mistake
again.
4. Don't start with the electronic test equipment, start with some analytical
thinking. Many problems associated with instrumentation equipment do
not require a schematic (though one may be useful).
5. Many problems have simple solutions. Don't immediately assume that
your problem is some combination of esoteric complex convoluted
failures. For a TV, it may just be a bad connection or failed diode. For a
VCR, it may just be a bad belt. For a CD player, a dirty lens or need for
lubrication. Try to remember that the problems with the most
catastrophic impact on operation - a dead TV or a VCR that eats tapes -
usually have the simplest solutions. The kind of problems we would like to
avoid at all costs are the ones that are intermittent or difficult to
17 | P a g e
reproduce: subtle color noise, the occasional interference, or the dreaded
horizontal output transistor blowing out every 3 months syndrome.
6. Whenever possible, try to substitute a working unit. With modular
systems like component stereos and computers, narrowing down a
problem to a single unit should be the first priority. This is usually safe to
do in such cases and will quickly identify which unit needs work. This
same principle applies at the electronic or mechanical parts level. Note
that there is the possibility of damaging the known good part by putting it
into a non-working device or vice versa. This risk is most likely with the
power circuitry in amplifiers, TVs and monitors, power supplies, etc. With
appropriate precautions (like the series light bulb) the risk can be
minimized.
7. Don't blindly trust your instruments. If you get readings that don't make
sense, you may be using your equipment in a way which is confusing it.
DMMs are not good at checking semiconductors in-circuit or the power
transistor you are testing may have a built in damper diode and/or base
resistor. Your scope may be picking up interference which is swamping
the low level signal you are searching for (TVs and Monitors, or low level
circuits in VCRs and CD players). Your frequency counter may be double
triggering due to noise or imperfect signal shape.
8. Realize that coincidences do happen but are relatively rare. Usually, there
is a common cause. For example, if a TV has no vertical deflection and no
picture, it is much more likely that a common power supply output has
failed than for parts in both the deflection and video subsystems to be
bad. In other words, first look for a common root cause rather than trying
to locate bad parts in separate circuits.
9. Exceptions include lightning, power surge, dropped, water, or previous
repair person damaged equipment. However, multiple electrolytic
capacitors in older equipment may be degrading resulting in failures of
18 | P a g e
unrelated circuits. Determine if all the problems you are troubleshooting
have just appeared.
10. Confirm the problem before diving into the repair. It is amazing how
many complaints turn out to be impossible to reproduce or are simple
cockpit error. It also makes sense to identify exactly what is and is not
working so that you will know whether some fault that just appeared was
actually a preexisting problem or was caused by your poking. Try to get
as much information as possible about the problem from the owner. If
you are the owner, try to reconstruct the exact sequence of events that
led to the failure.
11. Get used to the idea of working without a schematic.
12. Whenever working on precision equipment, make copious notes and
diagrams. You will be eternally grateful when the time comes to
reassemble the unit. Most connectors are keyed against incorrect
insertion or interchange of cables, but not always. Apparently identical
screws may be of differing lengths or have slightly different thread types.
Little parts may fit in more than one place or orientation. Etc.
13. Select a work area which is wide open, well lighted, and where
dropped parts can be located - not on a deep pile shag rug. The best
location will also be relatively dust free and allow you to suspend your
troubleshooting to eat or sleep or think without having to pile everything
into a cardboard box for storage.
14. Understand the risk of ESD - Electro-Static Discharge. Some
components (like ICs) in solid state electronic devices are vulnerable to
ESD. There is no need to go overboard but taking reasonable precautions
such as getting into the habit of touching a safe ground point first.
19 | P a g e
devices. You shouldn't be touching components with the device powered and
plugged in (at least, not until you really know what you are doing!). Once
unplugged, sheet metal shields or other ground points should be safe and
effective.
While capacitors will occasionally leak making diagnosis easy, in most cases,
there are no obvious signs of failure. (Note: Don't be misled into thinking
that the adhesive often used to anchor large capacitors and other
components to the circuit board are leakage.) The most useful testing device
for electrolytic capacitors is an ESR meter. However, heating suspect caps
with a hair dryer may get the equipment going for the purposes of making a
diagnosis.
Problems that result in a totally dead unit or affect multiple functions are
generally power supply related. These are usually easy to fix. Common
failure items are the large hybrid power regulator ICs used in many VCRs
20 | P a g e
and TVs, diodes and transistors, and remarkably - high value resistors
that open up.
Catastrophic failures often result in burnt, scorched, cracked, exploded, or
melted components, or similar catastrophic consequences. However, some
components run hot by design and slight discoloration on the circuit board
in their vicinity, while not desirable, may be normal. Use your senses of
sight and smell for the preliminary search for such evidence.
Listen for signs of arcing or corona - snapping or sizzling sounds. A
component on the brink of failing due to overheating may provide similar
audible clues.
Many CD player problems are mechanical - dirty lens, worn or oily drawer
belts, dirt/gummed up grease on sled tracks/gears, bad/partially shorted
spindle or sled motor. Power problems with portables seem to be common
as well. No matter what the symptoms, always make it a habit to clean
the lens first - many peculiar failure modes are simply due to a dirty lens.
Actual laser failure is relatively uncommon despite what the typical service
shop may claim. CD players are also remarkably robust. Optical alignment
should never be needed under normal conditions of operation.
TV and monitor problems are very often power supply or deflection
related. These tend to have obvious causes - blown posistor, rectifier
diodes, filter capacitor, HOT, or chopper. Flyback with shorted windings or
shorts between windings or in the voltage multiplier (if used) or
screen/focus divider network are also common. Where the HOT or chopper
is involved, operation should be observed after the repair as components
in the vicinity may cause the new parts to fail. HOTs should generally not
run hot. If they do, check for weak drive, excess B+, etc.
Ink-jet printers are extremely reliable electrically. Look for simple problem
such as caked ink in the 'service station' area, misaligned print-head
21 | P a g e
contacts, or a nearly empty cartridge when erratic printing problems
develop.
Laser printers tend to develop problems in the fuser, scanner, or power
control modules. These are often simple like a burned out lamp, bad
motor or bad connections.
Logic circuits - marginal timing or signal levels will result in a dramatic
change in behavior with a slight 'body' load. It has been possible to locate
a race condition or glitchy signal on a 305 pin PGA chip using this
approach in less time than it would have taken to roll the logic analyzer
over to the system under test. Signals which have proper levels and
timing are generally remarkably immune to this sort of torture.
Analog circuits - behavior can again be altered. In the case of audio
amps, probing with a finger is just as effective as the use of a signal
injector - which is what you are doing - and the equipment is always
handy. By evoking hum, buzz, clicks, and pops, locating the live or dead
parts of a circuit is rapid and effective.
Unknown circuits - where no schematics are available, it may be
possible to get the device to do something or locate an area that is
sensitive to probing. The function of a section of circuitry can often be
identified by observing the effects of touching the components in that
area.
Bad bypass capacitors - touching the power/signal side of a good
bypass cap should result in little or no effect. However, a cap with high
ESR and/or reduced uF will not be doing its job bypassing the pickup from
your finger to ground - there will be a dramatic effect in audio or video
systems.
Don't get carried away - too much moisture may have unforeseen
consequences.
22 | P a g e
Depending on the condition of your skin, a tingle may be felt even on low
voltage circuits under the right conditions. However, this is pretty safe for
most battery operated devices, TTL/CMOS logic, audio equipment (not high
power amps), CD players, VCRs (not switching power supply), etc.
WARNING: Make sure you do this only with LOW VOLTAGE circuitry. You
can easily fry yourself if you attempt to troubleshoot your TV, computer
monitor, photoflash, or microwave oven in this manner!
23 | P a g e
Practical 4
Aim: At the end of this session, the students will be able to test
semiconductor diodes and transistor to ascertain whether they are good.
Discussion:
One of the nice things about solid-state devices is that, under normal
conditions, they rarely go bad. However, "rarely" is not the same as "never".
And if conditions are not "normal", if an excessive voltage gets to a
semiconductor, it can be damaged. In this article we will discuss how to test
for a damaged transistor or diode.
Procedures:
Measure the diode resistance both ways. One way the meter should indicate
an open circuit (infinity), the other way you should get a reading (often a
reading around 600). That indicates the diode is good. If you measure an
24 | P a g e
open circuit both ways, the diode is open. If you measure low resistance
both ways, the diode is shorted.
The procedures described above assume the diode under test is not part of
any circuit. If you are trying to test a diode that is on a circuit board or
otherwise connected to other components, then you should disconnect one
end of the diode. On a circuit board you can unsolder one end of the diode
and lift it off the board. Make sure that you first disconnect all power going
to the circuit before you disconnect the diode. After disconnecting one end,
proceed as described above.
One reason to know the polarity of your meter is so you can determine
which end of a diode is the cathode if the band has been removed. Also, as
we will see below, you can use your Ohm-meter to tell an NPN transistor
from a PNP if you know which meter lead is positive.
25 | P a g e
4. Testing Zeners
If you just want to know if a Zener diode has opened-up or shorted-out,
then just test it as described above for standard diodes. If you want to
measure its Zener voltage level, you will have to build a circuit as shown in
Figure 3.
The power supply voltage should be set to a value slightly higher than the
Zener value. For example, for a 12 volt diode, the supply voltage should be
about 15 volts. The value of the resistor R should limit the current to about a
milliAmp. For example, using 15 volts with a 12 volt Zener, use a 3.3K
resistor. The exact value is not critical. Once the circuit is built, just read the
Zener voltage off the meter (if you read 0.6 volts, reverse the diode).
NOTE: Any diode will become a Zener diode if you apply enough voltage to
it.
5. Testing LEDS
LEDs have a larger voltage-drop across them than regular diodes. Depending
on the LED, the drop can be between 1.5 to 2.5 volts. If you have a DMM
with a diode setting on the Ohms scale, then you may be able to test an LED
as you test a standard diode. The difference will be that the meter will read
1600 or 50 when the diode conducts instead of the 600 you read on a silicon
diode.
26 | P a g e
If you can't use your multi-meter, then build the circuit shown in Figure
4 and see if the LED light up.
If the LED doesn't light up; reverse polarity on the diode. If it still doesn't
light, it's bad.
Transistors
As with diodes, it is usually the case that a transistor either works or it
doesn't. So again we will be able to make a few simple tests with a meter to
see if a transistor is good or bad. You can think of a transistor as two back-
to-back diodes in one package as shown in Figure 5.
Note that transistors come in two basic types: NPN and PNP. The letters C,
B, E stand for COLLECTOR, BASE, and EMITTER which are the names of the
three leads which come out of a transistor.
6. Testing Transistors
Assuming you know if the transistor is NPN or PNP, and assuming you know
where B, C, and E are, then just test the B-C junction and the B-E junction
27 | P a g e
as if they were standard diodes. If one of those junctions is a "bad diode",
then the transistor is bad. Also, check the resistance from C to E using a
higher Ohms scale (say, the 2 Meg scale). Be sure your fingers don't touch
the metal test points or you will just measure your skin resistance. If the
transistor is good, you should get an open-circuit reading from collector to
emitter.
NOTE: the above assumes silicon. With germanium transistors you may
measure a high resistance from C to E.
28 | P a g e
Some transistors are Darlingtons. They have a higher reading base to
emitter which may appear as an open on a VOM.
29 | P a g e
Practical 5
Topic: Transistor circuit test and fault finding using a multimeter
Aim: To identify fault in a faulty equipment using multimeter
Discussion:
One of the main uses for multimeters whether they are analogue
multimeters or digital multimeters, DMMs is to test and fault find circuits like
those in a transistor radio. Multimeters are ideal items of test equipment for
finding many faults in a transistor circuit. However to use a multimeter to
test a circuit and find faults it is necessary to have a little knowledge about
the circuit, and also to adopt a logical approach in tracking down any faults
that may exist.
Word of warning!! Some transistor equipment may be mains powered.
Only qualified persons should attempt to repair mains powered equipment or
equipment that contains high or hazardous voltages. High voltage
scan kill so be warned!
Procedure:
Look for obvious faults
The first step when looking at tracing any faults and testing a transistor
circuit of any sort is to look for the obvious or major faults. Fortunately most
faults with electronics equipment such as transistor radios are relatively
major and therefore easy to find. Accordingly the first step in any fault
finding is to look for the major problems.
1. Check the supply to the circuit: The first steps in checking the circuit
are to ensure that it has power being supplied to it. This is easily done
using a multimeter set to a voltage range. Measure the voltage using a
multimter at the points where the supply enters the circuit board. If the
multimeter indicates that there is no supply voltage then there can be a
number of possibilities to investigate:
o Battery could be flat if the equipment is battery powered
30 | P a g e
o If the transistor equipment is battery powered, the battery could have
been left in for many months and corroded the battery compartment.
Check for this and if there are signs of leakage then clean and remove
all signs of corrosion being careful not to touch any of the residue.
o On-off switch may be faulty: This can be checked by disconnecting any
power source and checking for continuity across the switch.
o Corroded connector: One common problem is that connectors become
corroded with time and connections can become very poor, especially
of the equipment has not been used for some time. To overcome this
it can help to unplug and then re-mate the connector.
o Check for any broken wiring that would prevent the power reaching
the circuit board.
2. Check the outputs from the board: In the same way that broken
connections may exist for the power line, the same may be true of the
outputs from the board. Again it is worth checking any connectors that
may have corroded or oxidised with time, and check for any broken
connections.
3. Check the inputs to the circuit: Likewise, if the signal inputs are not
reaching the board then it will not be able to perform. Again any switches
and connectors along with any broken wires should be checked. Often a
multimeter can be used to check the continuity of the wires, but first
ensure there is no power applied to the circuit.
By using a multimeter for the fault finding, it is possible to find many of the
obvious faults that can occur. If the problem cannot be found, and it appears
that the correct power is reaching the transistor circuit, and the inputs are
all connected and present as well as the output lines being intact, then
further fault finding on the transistor circuit board itself may be needed.
Again a multimeter can assist in this.
31 | P a g e
4. Expected voltages in a transistor circuit
If all the inputs to the board appear to be correct, further tests can be
undertaken using a multimeter for the fault finding and to track down the
problem. Again a systematic approach should be adopted.
When testing a particular transistor circuit, a multimeter can be used to
determine if the voltages around the circuit are correct. To test and fault find
a particular transistor circuit, it is necessary to have an idea what the steady
voltages should be. The circuit below is a typical basic transistor circuit.
Many circuits are similar to it, and it provides good starting point to explain
some of the points to note.
32 | P a g e
Assume the circuit is operating in a linear mode, i.e. it is not a
switching circuit.
Assume the circuit is operating in a common emitter mode as shown in
the diagram.
Assume the circuit has a resistive collector load.
If the assumptions above are true, then the following voltages can be
expected. If not then allowances need to be made for the changes.
1. The collector voltage should sit at approximately half the rail voltage.
More specifically it should sit at half the rail voltage less the emitter
voltage. In this way the greatest voltage swing can be obtained. If the
transistor has an inductive load, as in the case of the intermediate
frequency amplifier in a radio which may have an IF transformer in the
collector circuit, then the collector should sit at virtually the same
voltage as the rail voltage.
2. The emitter voltage should sit at around a volt or two. In most class A
common emitter circuits an emitter resistor is included to give some
DC feedback. The voltage across this resistor is typically a volt or so.
3. The base voltage should sit at the PN junction turn on voltage above
the emitter. For a silicon transistor, which is the most common type,
this is around 0.6 volts.
33 | P a g e
In addition to this there are many other types of circuit which may need
fault finding. Switching circuits are quite common these days where
transistors are used to drive other elements such as relays or other devices.
These do not operate in a linear mode. Instead all voltages are either on or
off. The collector voltage will either be approximately zero when the
transistor is on, and approximately the rail voltage when off. The emitter will
usually be connected to ground, and the base voltage will be high, i.e.
approximately 0.6 volts for a silicon transistor when the transistor is on (i.e.
collector near zero), and low, (zero volts) when the transistor is off and the
collector is high.
Summary
A multimeter is an ideal piece of test equipment to help with fault finding in
an electronics transistor circuit. Often circuits like transistor radios fail after
they have been used for many years, and it is useful to be able to mend
them Also when constructing equipment, circuits do not always work first
time and it is necessary to fault-find these circuits. While it will not be
possible to solve all problems using a multimeter, it is one of the most useful
basic tools for any fault finding job.
34 | P a g e
Practical 6
Discussion:
Automation technicians are constantly challenged to keep instrumentation
loops and I/O working at peak efficiency in the least amount of time
possible. While multiple tools have typically been needed to perform various
troubleshooting tasks, today's multi-function instruments, such as mA
process clamp meters, allow technicians to perform a wide range of tests
with outstanding accuracy and efficiency, while cutting down on the number
of instruments needed to do the job.
As these tools become increasingly important in today's automation and
process control environments, it is important to understand when, where
and how to use them to their best advantage - from tracing control loop
problems or malfunctions to field testing and commissioning.
Following is a look at some of the features and functions of mA process
clamp meters, along with troubleshooting guidelines to help you get the
most out of your instrument investment.
1. Tracing Control Loop Problems: Often, the first indication of a control
loop problem comes from the operator reporting a bad valve or a loop not
responding the way it should. Any of these anomalies is a signal for the
technician to begin troubleshooting.
The first step is to measure the 4-20 mA signals to verify the loop current
value. There are three likely causes when the loop current measured is not
as expected: broken, disconnected or shorted wires; a bad loop power
supply; or faulty instrumentation. If no problem is found in the wires, check
the loop power supply. If that supply shows no output, a meter with a 24-V
loop power function can be used to substitute for the missing output. If the
35 | P a g e
loop works properly, then the source of the problem is obviously the power
supply.
When the wiring and power supply both check out, it's time to check the
transmitter. Use the mA simulate mode on a loop calibrator, process
calibrator or multi-function clamp-on meter to substitute for the transmitter.
If the loop performs as requested, the problem lies with the transmitter.
Finally, if a final control element (i.e. a valve positioner) is suspected, the
mA source/simulate mode can feed a signal into the element and provide a
response.
For a final control element, use a clamp-on meter to measure loop current
and compare the value to the local position indicator on the valve or other
final control element. Relay that information to the operator to verify your
findings. In the case of a measurement loop, use the clamp meter to
measure loop current, then check with the operator to see how well the
value indicated on the control panel agrees with the actual loop current. This
will provide a quick check on the PLC or DCS I/O card that handles that
particular loop. It's also possible to use the meter's mA source/simulate
mode to send a known signal to the control room; and compare the value as
read by the operator to the actual current in the loop.
36 | P a g e
identical and isolated mA output. That output can be fed to a DMM with a
logging function to enable recording over time.
Classic troubleshooting involves checking the wiring, the power supply and
the control system's I/O cards (i.e. using the meter to inject a signal into the
I/O, and then contacting the operator to ask what he sees). If the operator
agrees with what is being sent, then there may be something amiss with the
transmitter - either the transmitter itself or, if this is a new installation, the
wiring.
4. Checking DCS and PLC I/O Cards: A mA process clamp meter can also
be used as an accurate signal source to check the operation of I/O cards on
PLCs and DCSs. For 4-20 mA input cards, disconnect the process loop and
use the meter's mA source mode to feed in a known signal value and
compare it to the value shown on the operator's readout. Voltage input cards
can be checked in a similar way, using the meter's voltage source function.
37 | P a g e
clamp-on current measuring function. A two-channel simultaneous
source/measure function can be used for valves that report their position
using 4-20 mA. An mA process clamp meter can also be used to feed in a
signal to a variable frequency drive (VFD) to simulate a normal input while
the technician observes the result.
38 | P a g e