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Basictroubleshootingpwrpt 12666111765285 Phpapp02
Basictroubleshootingpwrpt 12666111765285 Phpapp02
STRATEGY
Developing a
Functional Search Strategy for an
Effective Basic
Troubleshooting Process
Developed and presented by Bob Lonzo
BASIC TROUBLESHOOTING
COURSE OVERVIEW
• Course Objectives
• What is troubleshooting?
• Troubleshooter Styles
• Basic Troubleshooting
Search Strategy
BASIC TROUBLESHOOTING
COURSE OBJECTIVES
This course is designed to present to
the participant a Basic Troubleshooting
Search Strategy that can be used to
troubleshoot and identify malfunctions
in any type of industrial process
environment.
BASIC TROUBLESHOOTING
COURSE OBJECTIVES
Upon completion of this course, the participants
will be able to;
BASIC TROUBLESHOOTING
COURSE OBJECTIVES
Upon completion of this course
the participant will be able to:
BASIC TROUBLESHOOTING
COURSE OBJECTIVES
• Demonstrate the how to utilize
WD machine drawings
to obtain data.
• Breaks
• Lunch Break
• Safety Concerns
Adhere to all Plant Safety rules
Evacuation Route
BASIC TROUBLESHOOTING
TROUBLESHOOTING DEFINED
The Definition of TROUBLESHOOTING is
“To operate or serve as a troubleshooter”
BASIC TROUBLESHOOTING
TROUBLESHOOTING DEFINED
The Definition TROUBLESHOOTER is;
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
GAMBLERS
TESTERS
THINKERS
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
GAMBLERS
• WANDERERS
• RISK TAKERS
• ODDSMAKERS
• SWAPPERS
BASIC TROUBLESHOOTING
BASIC TROUBLESHOOTING
WANDERER
• Relies completely on random chance to
find the problem!
BASIC TROUBLESHOOTING
BASIC TROUBLESHOOTING
WANDERER
• Conducts exhaustive search by checking
everything in the system!
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
RISK TAKERS
• Reconfigures the system to
provide new information!
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
ODDSMAKERS
• Rely on knowledge of
common fault occurrences!
• Troubleshooting requires an
increasing level of skill!
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
SWAPPER
• Most encouraged form of gambling!
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
SWAPPER
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
TESTERS
• SENSORS
• TRACERS
• SPLITTERS
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
SENSORS
• Likes to look, listen, touch, and smell!
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
TRACERS
• Generally use
schematics/prints!
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
TRACERS
• Start from a faulty symptom
and
search backward to the
error’s
source!
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
SPLITTERS
• Divide & Conquer!
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
SPLITTERS
• Disconnect portions of a system
or circuit!
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
THINKERS
• READERS
• RECALLERS
• DESIGNERS
• ANALYZERS
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
READER
• Least skilled form of the
“Thinking” approach!
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
RECALLERS
• Rely more on their memory of
symptoms and solutions from
many years of experience!
• Rarely efficient!
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
ANALYZERS
• Highly skilled troubleshooters!
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
ANALYZERS
• Relies on
FUNCTIONAL SEARCH STRATEGIES
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
What is your Troubleshooting style?
• GAMBLER
Wanderer, Risk Taker,
Oddsmaker, Swapper
• TESTER
Sensor, Tracer, splitter
• THINKER
Reader, Re-caller,
Designer, Analyzer
BASIC TROUBLESHOOTING
TROUBLESHOOTING STYLES
• List any advantages to being a SWAPPER.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
SENSORY INPUT FILTERING ACTION
NO
YES
PROBLEM
DOCUMENTATION
SOLVED REPAIR
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
• SENSORY INPUT
Comprehension of the elements of observation
• FILTERING
Skill set for determining root cause of problems
• ACTION
Introduction to elements of hardware/software/documentation
to implement root cause analysis
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
• REPAIR
Show examples of necessary items
and information needed to affect repair
• DOCUMENTATION
Importance of documenting repairs
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
SENSORY INPUT
What is Sensory Input?
• Using your senses to gather data on the
problem.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
SENSORY INPUT
How do you Improve Sensory Acuity?
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
FILTERING
Root Cause Concept
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
FILTERING
Root Cause Concept
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
ACTION
From Thought to Action
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
ACTION
Examples of typical action skills are:
• Referencing WD Prints
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
FURTHER ACTION
Re-Action on the Filter
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
REPAIR
FIX IT!!!
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
DOCUMENTATION
Words for the Ages
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
STRATEGY
• List three examples of Sensory Input
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
DRAWINGS
The work area drawing depicts a dedicated area
of the plant comprised of;
• machinery
• control equipment
• personnel
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
DRAWINGS
Depending on the process, this
machinery may consist of
various pieces of
equipment.
Each executes a
programmed sequence
of operation that puts
the part(s) through various
stages of the production
Process.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
DRAWINGS
Area Drawings can be
used to Locate equipment
and controls.
Suggestions;
• Make notes on drawings
for reference.
• Identify control device
locations
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
DRAWINGS
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
DRAWINGS
• Tag Name
• Node Address
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
SEQUENCE OF OPERATION Station 25W Widget Assembler
• Details the sequence of a •
•
Operator places Widget Part W21 on conveyor
Widget Part W21 moves into assemble
position, pin clamps open.
given machine or process. • Widget Part W21 part present #1 and #2 detected.
• Widget Part W24 travels to Assemble position
above Widget Part W21
• Can be used to identify the •
•
Pin Clamps close on Robot Widget Part W21
The assemble process starts
• The W-frame press starts down over Widget
area of malfunction. Part W21 and Widget Part W24
• W-Frame (Press) continues down and stops
(dwell time).
• Problem is usually in the step •
•
The clamps extend.
W-Welder Robot spot welds Widget Part W21 and
Widget Part W24
just before the uncompleted • The W-frame press starts up from Widget Part W21
and Widget Part W24
step. • The clamps retract
• Widget Part W-25 ( combined W21 & W24) moves
on to conveyor
• Widget Part W-25 clears fixture
• Next sequence begins
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
HMI SCREENS
The Human Machine Interface (HMI)
is used to communicate with the
control system of the machines.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
HMI SCREENS
The Human Machine Interface (HMI)
is used to communicate with the
control system of the machines.
• A form of this
screen is located
on almost all
machine HMI’s.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
HMI SCREENS
• Displays are
typically color
coded (red and
Green) to indicate
normal or fault /
alarm status.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
TRACING LADDER LOGIC
ONLY TRAINED INDIVIDUALS SHOULD
ACCESS THE LADDER LOGIC.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
TRACING LADDER LOGIC
A trained individual can
use a Controller Work Remote
Run
station or a computer
loaded with specific
software to;
• View the ladder logic
program executing in
the controller.
• Modify logic
• An input signal or
output signal can be
viewed in real time by
accessing the ladder
logic of the controller
unit.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
TRACING LADDER LOGIC
• Tracing a signal in the
logic requires good
documentation of the
various controller logic
elements.
• An input signal or
output signal can be
viewed in real time.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
CONTROLLER SYSTEM INDICATORS
• Controller Systems usually have
Status indicators located on the
Controller and modules.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
CONTROLLER SYSTEM INDICATORS
Example : 1756-L55 Controller Module
Status Indicator Descriptions
RUN - Indicates mode of operation:
Solid Green – Processor is running
(reading inputs, executing logic, and
writing output data to enabled output modules)
Off – Processor is not controlling outputs
(processor could be in program mode,
test mode, or no power)
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
CONTROLLER SYSTEM INDICATORS
I/O - Indicates status of configured input and output
modules communication:
Solid Green – Processor is communicating to its
configured input and output modules
Flashing Green – One or more, but not all,
configured I/O modules is not communicating
Flashing Red – No I/O modules are
communicating or the processor has faulted
Off – No configured modules
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
CONTROLLER SYSTEM INDICATORS
FORCE - Indicates the presence and status of
forced I/O:
Off – No forces exist in controller
Flashing Yellow – Forces installed, but not active
Solid Yellow – Forces installed and active
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
MANUFACTURER MANUALS
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
MANUFACTURER MANUALS
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
MANUFACTURER MANUALS
Type Code Fault Description Recovery
1 1 The controller pow ered on in Run mode. Execute the pow er-loss handler.
3 16 A required I/O module connection failed. Check that the I/O module is in the chassis.
code data. 3
3
20
23
Possible problem w ith the ControlBus chassis.
At least one required connection w as not
more information about the fault.
Not recoverable - replace the chassis.
Wait for the controller I/O light to turn green
(See AB Controller 4 16
established before going to Run mode.
Unknow n instruction encountered.
before changing to Run mode.
Remove the unknow n instruction. This probably
happened due to a program conversion
4 83 The data tested w as not inside the required limits. Modify value to be w ithin limits.
4 84 Stack overflow . Reduce the subroutine nesting levels or the
number of parameters passed.
4 89 In a SFR instruction, the target routine does not Correct the SFR target or add the missing step.
contain the target step.
6 1 Task w atchdog expired. User task has not Increase the task w atchdog, shorten the
completed in specified period of time. execution time, make the priority of this task
“higher,” simplify higher priority tasks, or move
some code to another controller.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
MAINTENANCE LOGS
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
MAINTENANCE LOGS
• Early detection can be achieved by recording a
“baseline” of selective parameters such as
voltages and average readings for each major device
and periodically checking for deterioration.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
MAINTENANCE LOGS
• Once the baseline data is established, periodic
checks of the actual network data can be
compared to the baseline and potential
malfunctions addressed prior to becoming
shutdown situations.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
MAINTENANCE LOGS
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING TOOLS
Troubleshooting Worksheet
MAINTENANCE LOGS
Fill in the form to help you keep track of your troubleshooting effort. Exercise #
Other (specify):
BASIC TROUBLESHOOTING
ACTION I understand what happened. Now I determine what to do about it.
THE BASIC TROUBLESHOOTING TOOLS
MAINTENANCE LOGS
REPAIR Fix the problem and verify that it works.
Yes No Findings
Basic Troubleshooting
Questions
Were you able to fix the problem? Strategy
Is the line now in Automatic and ready to
run?
• Repair
Do you feel that the root cause was fixed?
• Documentation
DOCUMENTATION Finishing the effort by documenting your findings for others
• Adds Section for
Yes No Findings
Questions
Is there a logbook to fill out on this line? your Comments and
Was it necessary to update files after the suggestions
repair?
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
Review
TESTERS
• Likes to look, listen, touch, and smell!
• Valuable strategy for obtaining important information!
• Rarely a stand-alone problem solving method!
• Generally use schematics/prints!
• Performs voltage checks, continuity checks, or signal tracing!
• Start at a known good point in the system and work
toward the fault!
• Start from a faulty symptom and search backward to
the error’s source!
• Depends heavily on good test equipment and
schematic/print reading skills!
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
Review
TESTERS
• Divide & Conquer!
• Half split method!
• Successive approximation!
• Divide a system or circuit in half and check for proper
readings, then continue to divide and check!
• Use jumper wires
• Disconnect portions of a system or circuit!
• May contribute to confusion because of the induced
interaction of components!
• Potential for damage to equipment or injury to personnel!
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
Review
THINKERS
• Least skilled form of the “Thinking” approach!
• Highly recommended in many situations!
• Instances still arise to troubleshoot manually!
• Must be able to switch to another style of troubleshooting!
• Rely more on their memory of symptoms and solutions
from many years of experience!
• Troubleshooting needs continual practice!
• Tend to lose troubleshooting skills!
• Solve common problems in familiar systems!
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
Review
THINKERS
• Use theoretical knowledge to evaluate faults!
• Rarely efficient!
• Highly skilled troubleshooters!
• Use system knowledge and observations (sight) of
symptoms to eliminate portions of a system in a logical
way!
• Requires a detailed understanding of the system!
• Think before you approach!
• Relies on FUNCTIONAL SEARCH STRATEGIES
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
Review
DRAWINGS
• The work area drawing depicts a dedicated area
of the plant comprised of; machinery , control equipment,
and Personnel
• Area Drawings can be used to Locate equipment and
controls.
• Drawings can also indicate the various control devices,
associated sensor devices, and their tag names
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
Review
SEQUENCE OF OPERATION
• Details the sequence of a given machine or process.
• Can be used to identify the area of malfunction.
• Problem is usually in the step just before the uncompleted
step.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
Review
HMI SCREENS
• The Human Machine Interface (HMI) is used to
communicate with the control system of the machines.
• HMI devices are used to; Check the operation status of a
Machine, Permit operator to modify operation, and
Provide alarms and warnings
• Displays are typically color coded (red and Green) to
indicate normal or fault / alarm status.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
Review
Trace Ladder Logic
ONLY TRAINED INDIVIDUALS SHOULD ACCESS THE
LADDER LOGIC.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
Review
MANUFACTURER MANUALS
• Equipment manufacturers often times include a
troubleshooting
section in the machine manuals.
• Check the manuals for hints on detecting and preventing
malfunctions
• Manuals provide error code data.
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
Conclusion Module One
Using the Basic Troubleshooting Strategy improve
Your troubleshooting ability and result in:
• Increased production
• Reduced down
• Confident Workforce
BASIC TROUBLESHOOTING
THE BASIC TROUBLESHOOTING
Conclusion Module One
Thank you for your attention.
BASIC TROUBLESHOOTING