Phase 40: Troubleshooting & Maintenance

This phase contains 5 sections and 34 checklist topics. Use the interactive phase page to track your own learning progress.

Electrical faults

  • Fuse blown
  • MCB trip
  • OLR trip
  • Contactor not energizing
  • Motor not starting
  • Wrong rotation
  • Phase loss
  • Missing control voltage

PLC

  • Input missing
  • Output missing
  • CPU fault
  • Program fault
  • Module fault
  • Communication fault
  • Network fault

Instrumentation

  • 4-20 mA fault
  • Sensor fault
  • No signal
  • Wrong scaling
  • Noise
  • Calibration error

VFD

  • OC
  • OV
  • UV
  • Overtemperature
  • Motor fault
  • Communication fault

Practical Field Additions

  • Preventive versus corrective maintenance planning
  • Build a symptom -> evidence -> root cause -> corrective action report
  • Distinguish electrical, PLC, field instrument, network and SCADA faults
  • Investigate recurring failures using fault history and trends
  • Replace and validate a faulty module in a safe simulation/training rig
  • Coordinate technical fault resolution with customer and vendors
  • Verify and document condition after repair or modification

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