Troubleshooting

Instrumentation Systems

Fluid Control Research Institute INDIA www.fcriindia.com

Garbage In, Garbage Out: GIGO

GIGO applies to cases where faulty measurements result in faulty outputs. Poor measurements fool even the best control systems Failures at Sensors/transmitters, Power Supply, Fuse cabling & terminations, grounding Process impulse lines, connections

Systematic Approach to troubleshooting

Describe the fault/defect. What works and what doesnt Identify possible causes. Internal? External? Software? Hardware? Evaluate possible causes and confirm true cause. Is it due to this? How would unit perform with/without the specific signal / module / power / etc.? Take corrective action

Systematic Approach

Initial Investigation Gather as much available information on the problem as possible even before touching the
.

system . Consult logbook on the instrument/system actual user/operator may have noticed some unusual behaviour as a prelude to the existing problem/malfunction.

Preliminary checks Check for presence of dust and other foreign matter like loose-screws, solder bridges. Look for any unconnected cords, unplugged cards, cable- joints, unseated connectors, broken connections etc. If the unit had been serviced earlier and any alterations or modifications, links, cable-joints etc. had then been done, verify if malfunction or failure could be due to any defect on them.

Locating trouble/fault to modules/sections

To test the operation of each module in terms of input-output malfunctions. To isolate the malfunction to a particular section so that it can further be isolated to pinpoint the exact location and cause of the fault. relations and analyse for

Module or section level trouble shooting The board/module isolated from the system and without being powered on. Using simple tools like multimeters , check for continuity of connections and paths, open and short circuited paths, defective devices like diodes, transistors, resistors and capacitors . Further tracing/tracking tests may be done with system powered on.

Trouble shooting tools: Digital Multimeter, logic-probes, logic-pulsers, oscilloscope, good set of probes, cables, etc. Operation and service manuals: Enough knowledge of the basic system, its actions and performance under various operating modes/conditions. Availability of comprehensive manuals.

Shortcuts
Noting recurrent faults Through the experience of correcting a fault in a unit on one day and then encountering the same fault the next day. There is no need to go through the entire test at each time. Learning from the experience of others an engineer who has made a serious effort to solve a problem and feels he is not making any progress should approach others for help. should communicate to fellow engineers if he is to become more competent and efficient.

Checks
Fuses Open instrumentation loops, disconnects Impedance mis-matches, termination resistors Grounding at multiple ends Improper cable shields IS Barriers, Signal Isolators Noisy signal on Oscilloscope Incorrect Earth-Neutral potential at Power source

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