Repair LCD

7-Step Method for Electronic Troubleshooting
Ken Reed
System Improvements, Inc. 238 South Peters Road, Suite 301 Knoxville, Tennessee 37923 USA Phone: 865-539-2139 Fax: 865-539-4335 e-mail: ken@taproot.com web: www.taproot.com
Copyright 2007 by System Improvements, Inc. All Rights Reserved. Duplication Prohibited.
Scenario #1
You are enjoying a leisurely day by the pool. Man, its hot out here! Your wife calls from the kitchen door. The thermostat for the air conditioner is broke. Its getting hot in here! Consequences: Stress and discomfort
Copyright 2007 by System Improvements, Inc., Knoxville, TN. All Rights Reserved Worldwide. Duplication Prohibited.
Scenario #2
You are the maintenance supervisor at a coal mine. You must move 600 tons / hr out of the mine. You get a call from the control room. The conveyor belt is down again. It just shut off. You have about 1 hour before the hopper is empty and the rail cars are no longer being filled. Consequences: $400,000 / hr.
Scenario #3
You are the Reactor Control Chief on a nuclear submarine. You awaken when you hear all the ventilation fans turn off, and a loudspeaker announcement, Reactor Scram. The ship is currently operating under the north polar ice, with no place to surface within 6 hours. You have 3 ! hours left on battery power. Consequences: Real ugly
Which is worse??
Fix it NOW!!!
Ken Reed
Senior Associate System Improvements

Who am I?
21 years Nuclear Submarine Experience
Retired Master Chief Electronics Technician Served on:
Ballistic Missile Boat Fast Attacks Nuclear Research sub
Last boat USS SEAWOLF

Electronic Troubleshooting
Topics:
Electronic vs Other Equipment Before you start Troubleshooting Methods Organizing the Team Seven Step Process
Note About This Presentation

I am going by my experience, which often dictates a worst-case must fix scenario If your needs are not this critical, take what you need from what you see today
Troubleshooting Differences
Mechanical
Easier to see system Can put your hands on it Not much calculation Often, small number of alternatives
Electronic
Hard to visualize what a part does Black boxes, miniaturized May require extensive calculation Many directions to go
Troubleshooting Similarities
Requires knowledgeable troubleshooters Systems becoming more complex Lines blur between mechanical and electronic Must always look at entire system interaction
Operators are ALWAYS breaking the gear!
Why Does Troubleshooting Fail??

No formalized process in place No one in charge and looking at the Big Picture No one knows initial conditions No one is sure what has already been done Everything performed in series Pre-conceived idea of what caused problem
Before you start

Specify the goals of the troubleshooting Have plan in place to:
Gather initial data Notify team Preserve the evidence / indications Record troubleshooting progress / results
Organizing Your Team

Man in charge must be:
Designated and agreed upon Equipment expert, but not necessarily the guru Able to interface with team and management Able to see big picture. Do NOT get pulled into weeds of troubleshooting effort Knowledgeable of entire system interactions Organized and firm Able to multi-task
Organizing Your Team

Team may have all or some of the following:
Expert on the equipment that has failed Equipment operator
May be the one operating the gear when it failed
Parts procurement Data entry / extraction / computer guy LO/TO guy Runner (gopher)
7-Step Process General Comments

Write down everything. Do not depend on your memory.
Get initial data immediately.
In Parallel:
While waiting for initial steps to be completed, what can be done?

Gather maintenance history Get technical manual Obtain test equipment Immediately get observed symptoms from the operators
7-Step Process
1. 2. 3. 4. 5. 6. 7. Symptom Recognition Symptom Elaboration List of Possible Faulty Functions Localize the Faulty Function Localize the Faulty Circuit / Component Failure Analysis Retest Requirements
1. Symptom Recognition
Immediate Action
Immediate discovery of the problem by operator and supervisor
Who knows? Who should know? Who must be informed? Is equipment in a safe condition?
Procedure to record problem at operator level

Is there a policy in place?
10
Troubleshooting Team Arrives

This is much easier than you think Only list what actually caused the operator to recognize that there was a fault Do not include:
Operating conditions Other indications
What are goals?

Repair? Restore operation?
2. Symptom Elaboration
11
Symptom Elaboration
Operating conditions at the time
Start-up, shut-down, etc Power level, fluid levels Special operations in progress Recent maintenance Anything different than normal Exact sequence of switch operation
Other symptoms noted:

Alarms Warnings Blown fuses Smells Sounds
Include anything you think might be pertinent.
Symptom Elaboration
Man in charge Be ready to give options.
Can we operate in reduced status?
Lower throughput, less reliable, more likely to break something else, etc.
Can we by-pass the failed module (permission?) How long to implement each option? Risks for each option? How long can we operate with each option? What additional safeguards should be put in place?
12
Symptom Elaboration
Dont operate anything yet What permissions do you need to continue? This step in the process is where many troubleshooting plans break down.
Not all indications are listed Operator impressions / observations are not immediately obtained Nothing is written down
3. Possible Faulty Functions
13
Possible Faulty Functions

List all major functional blocks that could cause the problem: Dont Power supply eliminate anything Sensor unless you Amplifier can prove it! Etc We are not yet looking for the one specific failed component

This is where Equifactor can be used
Quickly look through Symptoms for problems available in the tables Gives you ideas what possible causes you should look for This is quick method of verifying what you think could be the cause Makes you think of problems outside your experience
14

You may want to have a Troubleshooting Guide assembled for most frequent or critical failures
Allows you to quickly get to this point Could be pulled directly from Equifactor, or even maintained in an Equifactor Custom Table Often in quick, flowchart format
4. Localize Faulty Function
15
Localize Faulty Function

Actual troubleshooting Permissions obtained Write down expected before you take a reading
Prevents seeing what you expect Youll talk yourself into whatever you observe
Write down EVERYTHING you do

May need to turn over Will want to look at it tomorrow

Man in charge Be ready to give further options.
More options may be available, now that you know what major component has failed.
Replace major function without knowing what exact component failed? What is risk of damaging new part without full failure mode known?
16
Equifactor Tables may have ideas on how this type of fault was troubleshot last time
Functional Troubleshooting Methodologies

Linear
INPUT Signal Output Signal
Test at each element Left to right Check input, output, power applied for each element
17

Half-split
INPUT Signal Check Good Check Bad Output Signal
Test each element Start in the middle Check input, output, power applied for each element

Easter Egg
INPUT Signal
Used because:
Not trained in any particular method No plan in place, therefore, just get going Not sure what has already been done
Most Popular?
Output Signal
18
5. Localize Faulty Circuit / Component
Localize Faulty Circuit / Component

This is troubleshooting to component level Troubleshoot down to lowest possible (expected) level May require specialized test gear Again, record everything you do
19
6. Failure Analysis
Failure Analysis
Prove to the team that the failure you found would cause ALL the symptoms you found. This prevents:
Replacing wrong component Having multiple undiscovered faults Talking yourself into your favorite failure
This is rarely done well
20
7. Retest Requirements
Retest Requirements
What retests will be required to prove the gear works?
Prove the new component is good Prove there are no other associated faults Prove you did not cause other damage during the troubleshooting or repair
May be required to officially recertify the system
21
Retest Requirements
Correct retests are required to ensure reactor safety.
Contained in a variety of manuals.
Maintenance & Replacement Instructions. Equipment Technical Manuals. Equifactor may provide guidance when a specific retest was used in the past Can be researched and pre-approved. Agreement on the correct retest requirements is a combined effort.
Plant Relationships
CAUTION: Actions taken during troubleshooting efforts can affect various plant capabilities.
22
Date: _________
TROUBLESHOOTING RECORD
Troubleshooters -
1. Symptom Recognition _______________________________________________ _______________________________________________ _______________________________________________ ________________________________________ _______ _______________________________________________ 2. Symptom Elaboration : _______________________________________________ _______________________________________________ _______________________________________________ _______________________________ ________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ 3. Possible Faulty Functions : _________________ _________________ _________________ __________________ _________________
Options !
Lower reli ability? By-pass interlock? How long to implement? Permission required? List risks Additional Safeguards
! ! ! ! ! ! !
Maint. History Plant Operating Manual Technical Manual Repair Parts Retests Area se t-up Test Equipment
_ ___________________ _ ___________________ _ ___________________ ___________________ _ ___________________
List operational options:
4. Localize Faulty Function : Test Point Expected Actual Sat/Unsat
______________________________________ _____ _____________________ _________ ____________ ___________________________________________ Copyright 2007 by System Improvements, Inc., Knoxville, TN. All Rights Reserved Worldwide. Duplication Prohibited.
5. Localize Faulty Circuit : Test Point Expected Actual Sat/Unsat
___________________________ _____________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ___________________ ________ _________________ ____________________ 6. Failure Analysis : ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ___ _____________________________________________________________ _________________ _________________________ ______________________ __________________________________________ _____ _________________ ___________________________________________________________ _____ _______________________________________________ __________ _______ 7. Retest Requirements : ________________________________________________________________ ________________________________________________________________ ______________________________________ __________________________ ________________________________________________________________ _______________________________________ _________________________ ________________________________ ______________________________ __ ________________ _____ ________________ ___________________________ _____________________ _____ ______________________________________ ___________________________________________________________ _____ __________________________ __________ ____________________________
23

Repair LCD

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Repair LCD

Încărcat de

Drepturi de autor:

Formate disponibile

7-Step Method for Electronic Troubleshooting

Senior Associate System Improvements

Last boat USS SEAWOLF

Note About This Presentation

Operators are ALWAYS breaking the gear!

Why Does Troubleshooting Fail??

Before you start

Organizing Your Team

Organizing Your Team

7-Step Process General Comments

Get initial data immediately.

While waiting for initial steps to be completed, what can be done?

Procedure to record problem at operator level

Troubleshooting Team Arrives

What are goals?

Other symptoms noted:

Include anything you think might be pertinent.

3. Possible Faulty Functions

Possible Faulty Functions

Possible Faulty Functions

Possible Faulty Functions

4. Localize Faulty Function

Localize Faulty Function

Write down EVERYTHING you do

Localize Faulty Function

Localize Faulty Function

Functional Troubleshooting Methodologies

Functional Troubleshooting Methodologies

Functional Troubleshooting Methodologies

5. Localize Faulty Circuit / Component

Localize Faulty Circuit / Component

This is rarely done well

May be required to officially recertify the system

_ ___________________ _ ___________________ _ ___________________ ___________________ _ ___________________

List operational options:

4. Localize Faulty Function : Test Point Expected Actual Sat/Unsat

5. Localize Faulty Circuit : Test Point Expected Actual Sat/Unsat

S-ar putea să vă placă și

_ ___________________ _ ___________________ _ _ _ _ ___________________