Phone: (908) 448 - 0302
Everything To Do with Controls
And Control Systems
20+ Years Experience
Owner:
Dan Hurley, CAP
There are many different types of troubleshooting techniques. Many people fall into a memory peg method of troubleshooting. They remember what caused a similar problem in the past and immediately implement the same solution that worked the last time. The shotgun method is also a popular method. The shotgun method involves changing out any and all parts that could possibly cause the problem. It generally gets results; however, there are times when it falls short or leaves the question of what caused the problem unanswered.
One of my old supervisors, Henry Menendez, pointed out that the first and probably best troubleshooting tools that anyone has, are their senses. Most electrical components smell when they burn out. If you look, sometimes you will see carbon stains from arcing when an electrical short occurs. If you listen, you can also hear things like chattering relays, small arcs and shorts, and the hum of a heavily loaded transformer. Henry also had another good piece of advice. He said, "Go for the simple things first. When there is more than one possibility, try fixing the easiest item first. Usually it's the simpler item anyway, and you end up looking like the hero for getting things up and running quickly."
After making initial observations and exhausting obvious remedies, it's time to step back and employ a logical approach. This is where most of us get frustrated and freeze up. The first thing to remember is that it is just a problem to be solved and there is nothing that can't be solved. Don't lose your faith in your own abilities - everyone sometimes hits a wall.
Step back, take a deep breath and employ the circuit divider method of troubleshooting. The first step in this method of troubleshooting is this - look for a logical division point in the system that is malfunctioning. In an electrical circuit, separate input from output. If the input is present then look to the output for the problem. Is the output a relay feeding a solenoid? Split the output at a logical point. Is the relay putting out an output? If yes move on to the solenoid. Is the solenoid shifting as it's supposed to? Is the solenoid controlling an air signal to a cylinder? Is the proper air pressure at the supply (Input/output again)? The one point that seems to get forgotten with cylinders that aren't operating correctly is the exhaust of the cylinder. In order for the air to actuate the cylinder, the cylinder needs to be able to exhaust the air that's in it. A plugged muffler has been the cause of more headaches than most people would care to admit as they tend to get moved to the new solenoid or cylinder when they are replaced. Again it becomes looking at input versus output.
Bottom line - if you find that you are stuck on a problem, you can call me.
One of my old supervisors, Henry Menendez, pointed out that the first and probably best troubleshooting tools that anyone has, are their senses. Most electrical components smell when they burn out. If you look, sometimes you will see carbon stains from arcing when an electrical short occurs. If you listen, you can also hear things like chattering relays, small arcs and shorts, and the hum of a heavily loaded transformer. Henry also had another good piece of advice. He said, "Go for the simple things first. When there is more than one possibility, try fixing the easiest item first. Usually it's the simpler item anyway, and you end up looking like the hero for getting things up and running quickly."
After making initial observations and exhausting obvious remedies, it's time to step back and employ a logical approach. This is where most of us get frustrated and freeze up. The first thing to remember is that it is just a problem to be solved and there is nothing that can't be solved. Don't lose your faith in your own abilities - everyone sometimes hits a wall.
Step back, take a deep breath and employ the circuit divider method of troubleshooting. The first step in this method of troubleshooting is this - look for a logical division point in the system that is malfunctioning. In an electrical circuit, separate input from output. If the input is present then look to the output for the problem. Is the output a relay feeding a solenoid? Split the output at a logical point. Is the relay putting out an output? If yes move on to the solenoid. Is the solenoid shifting as it's supposed to? Is the solenoid controlling an air signal to a cylinder? Is the proper air pressure at the supply (Input/output again)? The one point that seems to get forgotten with cylinders that aren't operating correctly is the exhaust of the cylinder. In order for the air to actuate the cylinder, the cylinder needs to be able to exhaust the air that's in it. A plugged muffler has been the cause of more headaches than most people would care to admit as they tend to get moved to the new solenoid or cylinder when they are replaced. Again it becomes looking at input versus output.
Bottom line - if you find that you are stuck on a problem, you can call me.
Electrical Lic # 16789