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Electrical Troubleshooting Quiz — July 3, 2018

July 3, 2018
Possible reasons for a recurring production line shutdown

A major customer needed a vendor to supply a high volume of a custom part on a regular basis. After some negotiation, your company landed the deal. Then your company had a special production system built just to make this product. The system has been producing below its rated capacity, due to shutdowns that happen unexpectedly. The capacity loss has caused slippage in meeting scheduled deliveries, and the customer is clearly displeased.

When a shutdown incident happens, the operator uses a dedicated radio to call it in; a tech arrives usually in less than three minutes. Typically, the repair tech unsuccessfully tries to restart the machine. Then he goes through the basic troubleshooting procedure, finds no problems, and restarts the machine. How might you find the problem?

The fact the machine starts after completion of the troubleshooting process indicates several possibilities. Examples:

  • Overheating. Determine what might be overheating, and put a recording temperature monitor on it. Consider calibrating or replacing any thermal protective devices.
  • Timing conflicts. If the system contains any timers, analyze the control logic for timing conflicts.
  • Door interlocks. Check the switch mounting and adjustment for these, and check any proximity switches.
  • Safety devices. The operator may be tripping a safety device, and even after the device is clear there’s a restart permission delay.

Also, determine what “As Found” and “As Left” data (e.g., temperatures, switch positions, etc.) may have a bearing on this issue.

About the Author

Mark Lamendola

Mark is an expert in maintenance management, having racked up an impressive track record during his time working in the field. He also has extensive knowledge of, and practical expertise with, the National Electrical Code (NEC). Through his consulting business, he provides articles and training materials on electrical topics, specializing in making difficult subjects easy to understand and focusing on the practical aspects of electrical work.

Prior to starting his own business, Mark served as the Technical Editor on EC&M for six years, worked three years in nuclear maintenance, six years as a contract project engineer/project manager, three years as a systems engineer, and three years in plant maintenance management.

Mark earned an AAS degree from Rock Valley College, a BSEET from Columbia Pacific University, and an MBA from Lake Erie College. He’s also completed several related certifications over the years and even was formerly licensed as a Master Electrician. He is a Senior Member of the IEEE and past Chairman of the Kansas City Chapters of both the IEEE and the IEEE Computer Society. Mark also served as the program director for, a board member of, and webmaster of, the Midwest Chapter of the 7x24 Exchange. He has also held memberships with the following organizations: NETA, NFPA, International Association of Webmasters, and Institute of Certified Professional Managers.

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