instructor guide - transit training network · 2017. 1. 30. · elevator-escalator –...

Instructor Guide

302: Advanced Electrical PrintreadingModule 5: Troubleshooting Exercises

Elevator-Escalator – Troubleshooting Exercises Instructor’s Guide

Table of Contents

1

Overview……………………………………………………………………………………………..…..……....4

Safety…………………………………………………………………………………………………………….10

Block and Function-block Diagrams……………………………………………………………………….13

Troubleshooting Hydraulic Sequence of Operation…………………………………………………….25

Troubleshooting PLCs………………………………………………………………………………………..31

Troubleshooting Call Circuits………………………………………………………………………………35

Summary………………………………………………………………………………………………………..39


Icons Used In This Guide Agenda Topic # Topic Title Duration

Total Time:

2

1

2

3

4

5

Overview

Block & Function-Block Diagrams

Hydraulic Sequence of Operation

Troubleshooting PLCs

Summary

30 Minutes

6

Troubleshooting Call Circuits

Field Trip

7

120 Minutes

20 Minutes

40 Minutes

30 Minutes

300 Minutes

20 Minutes

20 Minutes


Overview

Purpose The purpose of this module is to:

Objectives

At the end of this lesson, the transit elevator/escalator trainee will

be able to:

Materials Mandatory Make sure you have the following

Optional You may also want the following for optional

activities:

3

Provide the participant a means to further develop the craft

of troubleshooting by reading electrical prints in order to

troubleshoot escalator and elevator systems.

• PowerPoint Presentation

• Coursebook

• Quizzes

• Pencils

• Handouts: Additional Troubleshooting Note

Records for field trip

• Chalk board with chalk, large paper with

marker, etc.

• Internet connection

• Lab, simulator or out of service elevator

• Explain block and function-block diagrams used for

troubleshooting electrical problems.

• Troubleshoot hydraulic sequence of operation

• Troubleshoot a PLC problem using electrical diagrams

• Troubleshoot a safety circuit using electrical diagrams

• Troubleshoot a Call Circuit using electrical diagrams

Elevator-Escalator – Troubleshooting Exercises

DO SAY Materials Needed

Instructor’s Guide

In your own words:

Instructor’s Notes

4

Module Length: 300 min Time remaining: 300 min This section: 30 min (7 slides) Section start time: ________ Section End Time: ________

Welcome to the course on troubleshooting

exercises.

Advance

Riders depend on us. Troubleshooting

electronics in elevator and escalator systems

can be complex. Fortunately,

troubleshooting today is easier than in earlier

times.

Advance

PPT slides 1, 2 REVIEW introduction slides




In your own words:


5


Today we will

• Explain block and function-block

diagrams used for troubleshooting

electrical problems.

• Troubleshoot hydraulic sequence of

operation

• Troubleshoot a PLC problem using

electrical diagrams

• Troubleshoot a safety circuit using

electrical diagrams

• Troubleshoot a Call Circuit using

electrical diagrams

Advance

PPT slide 3 REVIEW module objectives




In your own words:


6


Lets take a look at some of the key words

we will be defining as move through this

module:

• Antistatic wrist strap

• Block Troubleshooting Diagram (Flow

Chart)

• Diagnostic Mode

• Ground clip

• Troubleshooting Note Record form

• Zener diode

Advance

PPT slide 4 REVIEW key terms




In your own words:


7

PPT slide 6 Thinking back to other courses or just in

general, what do we already know

about…..

• Block and function-block diagrams?

• Use of block and function-block

diagrams for troubleshooting?

• The hydraulic sequence of

operations?

• Troubleshooting?

• Use of electrical diagrams

troubleshooting?

Allow participants to think for a

minute and perhaps discuss with a

partner ideas as well as write down

any ideas. Discuss participant

responses and if possible list them on

a chalk board or similar. Advance


ASK

SMALL GROUP ACTIVITY

WRITE

Paper

Pencils or pens

Larger paper ,

chalk board, or

similar




In your own words:


8

PPT slide 6 Troubleshooting escalator and elevator

electrical and electronic systems takes time

and on-the-job experience to develop. Course

250, Troubleshooting, explored the

troubleshooting process, general strategies,

tips, pitfalls, and application procedures. You

may recall this troubleshooting process chart

with the 5 steps of troubleshooting.

This module helps the participant further

develop the craft of troubleshooting by

reading electrical prints in order to

troubleshoot escalator and elevator systems.

The method here is to discuss real-world

examples followed by exercises that the

participants and instructor can discuss in

training.

Advance

REVIEW slides





In your own words:


9

PPT slide 7 REFER participants to the source section

in the back of their course book.

With the kind permission of several escalator

and elevator manufacturers that work with our

transit authorities, this module draws on

practical examples in the transit field. These

companies are cited in the Sources section at

the end of this module. Each manufacturer

provides procedures for troubleshooting,

repairing, and replacing components should

there be malfunctions. Advance

REVIEW slides


REFER participants

Course book




In your own words:


10

PPT slide 8 When working on electrostatic devices, the

mechanic should always wear an antistatic

wrist strap or ground clip. This inexpensive

bracelet, demonstrated in Figure 1, is used to

safely ground a person working on very

sensitive electronic equipment, to prevent the

buildup of static electricity on their body which

can result in electrostatic discharge. Advance

REVIEW slides





In your own words:


11

PPT slide 9 REFER participants to Section 5.3 of The

Elevator Industry Field Employees’ Safety

Handbook

The Elevator Industry Field Employees’

Safety Handbook lists a number of guidelines

for precautions when working around

electrical circuits in Section 5.3, Energized Circuit Troubleshooting Checklist. Advance

REVIEW slides


REFER participants

The Elevator

Industry Field

Employees’

Safety

Handbook




In your own words:


12

PPT slide 10 Always remember these safety precautions:

On live circuits, use personal protective

equipment such as insulated tools,

nonconductive safety glasses or face

shield, clean leather gloves.

Always wear an antistatic ground clip

Follow guidelines in Elevator Industry

Field Employees’ Safety Handbook

Follow guidelines of your transit authority.

Advance

REVIEW slide





In your own words:


13

PPT slide 11 You probably may recall that block diagrams

are electrical drawings that show the

relationship between individual sections, or

blocks, of a circuit or system.

Advance The circuit device or component

inside each block is not shown

Advance and text describes the function of

the block. Block diagrams show the circuit,

device, or component.

Advance For example, a block diagram of

the network can show the connections among

sensors, actuators and automation systems in

an escalator system.

Advance Block diagrams can help the

mechanic check the devices or components

that are under suspicion of failure.

Advance

REVIEW slide





In your own words:


14

PPT slide 12 Here is an example of a block diagram

showing the relationship between individual

sections, or blocks of a DeviceNet for a Kone

escalator. You can see the blue call out

boxes showing how there is text used to

describe the function, and this is divided into

individual section.

Advance

REVIEW slide





In your own words:


15

PPT slide 12 Additionally, many manufacturers use block

troubleshooting diagrams,

Advance also referred to as flow charts, to

Advance help the technician troubleshoot

problems with YES or NO answers until the

problem is found. A flow chart shows the

logical sequence of steps for a given set of

conditions.

Advance Flow charts have the

troubleshooter follow a logical path when

trying to solve a problem.

Advance Flow charts use symbols and

interconnecting lines to provide direction.

Advance

REVIEW slide





In your own words:


16

PPT slide 14 REFER participants to their course book to

view close up diagrams of the following

slides.

Lets take a closer look at a block

troubleshooting diagram. Figure 3 in your

course book illustrates a troubleshooting flow

chart for a hall call problem taking the

mechanic from “This here hall call thing isn’t

working” through various fixes and possible

solutions. When all options have been

explored without a resolution, the mechanic

will have to put in a support call with the

manufacturer.

Advance

REVIEW slides


REFER participants

Course Book




In your own words:


17



slides.

So, we begin at the top of the diagram and

with the problem: “This here hall call thing aint

working.”

The first question indicated by this diagram

would be to ask if the installation is new?

Following the arrows, and if the answer is yes,

then the suggestion would be to verify all SC-

HCC board jumper settings.

On the other hand, if the answer is no, then

following the arrow after no would lead us to

the next question, “Are the SC-HCC green

lights on and all red lights off?”

Advance

REVIEW slides


REFER participants

Course Book




In your own words:


18



slides.

If the answer to “Are the SC-HCC green lights

on and all red lights off?” is no, then the

suggestion is to measure SC-HCDA output

DC volts and we have an additional

instruction to see Trouble Guide #1.

ASK If the answer to “Are the SC-HCC green

lights on and all red lights off?” is yes, what

does the chart suggest to do?

Allow participants to share answer.

Correct answer: Conduct shift F7-1 inventory

& lamp test. View the inventory. This takes

us to the next question, “Is the hall call station

mode inventory correct?"

Advance

REVIEW slides


REFER participants

ASK

Course Book




In your own words:


19



slides.

ASK If the answer to “Is the hall call station

mode inventory correct?” is no, then what

should the technician do?


Correct answer: Review Node Inventory

Trouble Guide #2

ASK And if the answer is yes?


Correct answer: Then move on to the next

question “Is the hall call lamp inventory

correct?”

And if the answer to that is no, then Review

Lamp Inventory Trouble Guide #3.

Advance

REVIEW slides


REFER participants

ASK

Course Book




In your own words:


20



slides.

ASK If the answer to “Is the hall call lamp

inventory correct?” is yes, then what should

the technician do?


Correct answer: Go to the next question, “Is

the system registering phantom calls? (false

calls created by poor grounding or excessive

RF noise)

ASK And if the answer is yes?


Correct answer: Review Bus Signal Errors

Trouble Guide #4

Advance

REVIEW slides


REFER participants

ASK

Course Book




In your own words:


21



slides.

ASK If the answer no to the question, “Is the

system registering phantom calls?”, then what

should the technician do?


Correct answer: Verify that all control signals

are being sent and received by the SC-HCC

card, see table 7, document all information

about the system, and then call MCE

technical support.

Advance

REVIEW slides


REFER participants

ASK

Course Book




In your own words:


22

PPT slides 20, 21 REFER participants to their course book

for Appendix 1 reviewing this example

block troubleshooting diagram.

Let’s practice.

Advance

We will use the MCE Troubleshooting

Seminar Manual in Appendix 1 in the back of

your course book for this activity.

Advance

ASK Who remembers this chart from Course

250, Troubleshooting?

Allow participants to share what they

remember.

We will use this chart to work through the

exercise now. Just like stated in 250, this

chart can be very helpful in the field when

troubleshooting.

Continued


ASK

CLASSROOM

ACTIVITY

Appendix 1

Course Book,

Troubleshooting Note

Record




In your own words:


23

PPT slides 21, 22 Please feel free to use this or similar format

in your own notes and records when you are

troubleshooting.

You may Direct participants to record

notes in their course book as they work

through the activity as a class.

Advance

ASK

Neither the UP nor the DOWN hall call

buttons illuminate on the first level of a three-

level elevator serving commuter parking at

the transit garage. The second and third

floor hall call buttons are OK. Using the flow

chart in Figure 3, what steps does the OEM

recommend the mechanic follow to

troubleshoot the problem?

Advance


ASK

CLASSROOM

ACTIVITY

Appendix 1

Course Book,


Record




In your own words:


24

PPT slides 23 ASK

What is the initial problem or complaint?

Call on a participant to state the initial

complaint.

Answer: Neither the UP nor the DOWN hall

call buttons illuminate on the first floor. The

second and third floor hall call buttons are

OK.

And we know the problem was reported by a

customer and verified by a station manager.

Use Appendix 1 to complete the

remainder of the chart with participants.

Advance


ASK

CLASSROOM

ACTIVITY

Appendix 1

Course Book,


Record




In your own words:


25

PPT slide 24 ASK: What do you know about sequence of

operation in general?

Allow participants to discuss possible

answers.

Advance

A sequence of operation is either a narrative

or schematic description of how the elevator

system automatically and optimally operates.

REFER participants to their course book.

Figure 4 is a chart showing a sequence of

operation for a hydraulic elevator. This is a not

a trouble-shooting chart but it does help the

mechanic to better troubleshoot a problem

within the context of the sequence of

operation. For example, it shows the

sequence of the door lock input (DLK) from

the controller to the up valve.

Advance

REVIEW slides


REFER participants

ASK

Course Book




In your own words:


26

PPT slide 25 ASK: What is nomenclature?


answers.

Advance

Nomenclature is a standardized set of terms

or symbols. For the following sequence of

operation we will look at, this is the

nomenclature we will use.


DLK – Door lock input

UPDO – Up direction output

H – High speed output

PCI/O – Power and call input

RB4 – Controller main relay

WYE – Wye-Delta contactor

AA – Starter pilot controller relay

BB – Motor transfer pilot controller relay

Advance

REVIEW slides


REFER participants

ASK

Course Book




In your own words:


27

PPT slide 26 ASK: Again, what is a sequence of

operation?


answers.

A sequence of operation is either a narrative

or schematic description of how the elevator

system automatically and optimally operates.

Advance

This s a chart showing a sequence of

operation for a hydraulic elevator. This is a not

a trouble-shooting chart but it does help the

mechanic to better troubleshoot a problem

within the context of the sequence of

operation. For example, it shows the

sequence of the door lock input (DLK) from

the controller to the up valve.


Advance

REVIEW slides


REFER participants

ASK

Course Book




In your own words:


28

PPT slides 27 Lets take a look at another example of a

problem for troubleshooting. A customer

gets on the elevator on Parking Level 2. She

presses the button to take her up to Parking

Level 3. The elevator car is lowered to the

bottom landing, Parking Level 1. What is the

likely problem?

Advance

What is the likely problem?

Advance

What steps does the OEM recommend the

mechanic follow to troubleshoot the

problem?

Advance


ASK

CLASSROOM

ACTIVITY

Appendix 1

Course Book,


Record




In your own words:


29

PPT slides 28, 29 Advance

So, let’s practice.

Advance

REFER: Participants to Appendix 2 in the

back of their course book.

Advance

Again, we will be using our troubleshooting

chart. Lets look at the information we already

know for the problem initially. We know:

Elevator car moves to the bottom landing

despite customer pressing the up button from

floor 2 of three level elevator. We also know

that a customer has reported the problem,

and this as verified by station management.

Direct participants to use Appendix 2 to

complete the troubleshooting chart.

Continued

REVIEW slides


REFER participants

Course Book




In your own words:


30

PPT slide 29 Allow participants to work in pairs to fill

in the troubleshooting chart using the

sequence of operation chart, the

appendix, and through discussion with

their partner.

After 10 – 15 minutes, bring the who

group back together.

Allow participants to share what they

wrote down. Guide them through the

discussion.

Advance


ASK

SMALL GROUP ACTIVITY

WRITE




In your own words:


31

PPT slide 30 You may recall the PLC reads inputs,

processes them through a program, and

generates outputs.

The PLC is often the first place for a

mechanic to begin troubleshooting, especially

if the problem resides in the PLC itself. In the

previous module to this course, the participant

examined PLC logic using software for

training purposes only. The participant also

examined schematics and diagrams that

identified input/output within each diagram in

order to troubleshoot a problem with the

transit escalator or elevator.

This section follows up on the previous

module in this course by outlining some PLC

troubleshooting methods which may be

helpful to the elevator-escalator transit

technician.

Advance

REVIEW slide





In your own words:


32

PPT slide 31 If properly installed and its environment kept

according to manufacturer’s

recommendations, the PLC will not be the

source of the problem most of time. The

following are the basic steps to take to cover

a majority of PLC-only related problems and

not problems related to field inputs and

outputs. PLC based problems are usually

either a hardware component problem or

software or program related problem.

Advance

REVIEW slide





In your own words:


33

PPT slide 32 Hardware component problem:

Visually inspect all LED lights in each of the

I/O slots, ensure they are lit.

If some lights on a card are out went they

should be lit, or all lights on a card are out,

then replace the card or cards.

If all lights are out starting from the memory

card to the end of the I/O slots, then test the

PLC power supply using a DMM. Test for

incoming voltage —120VAC at the input

terminals and the output voltage and

240 VDC at the output terminals. If input

voltage is present, but output voltage is not,

then test the power supply fuse. If the fuse is

good, then it is likely that the power supply is

defective and should be replaced.

I think this should be 240 and not 24 VDC –

unless Alex said differently.

Advance

REVIEW slide





In your own words:


34

PPT slide 33 If tests on the power supply show no

problems, then check for damage to the

backplane — the bus into which all cards tie

—and any ribbon cables. Replace any

damaged components.

Visually inspect for burn marks which is a

good indication that a ribbon cable needs to

be replaced. If no burn marks are visible, it

may be necessary to perform a continuity

test on the ribbon cable to check for openings

on the wires.

Advance

REVIEW slide





In your own words:


35

PPT slides 34, 35, 36 The other problem a PLC may have could be

in the software or program itself.

If there is a fault in the program, then the PLC

error LED located on the memory card will be

lit. In this case, a laptop should be connected

to the PLC for program diagnosis.

Manufacturer supporting software should be

pre-loaded onto the laptop prior to diagnostic

testing.

Advance

Next, we will look at troubleshooting call

circuits.

Advance


Here is the job print for call inputs of an

elevator that serves four levels.

Advance

REVIEW slides


REFER participants

Course Book




In your own words:


36

PPT slides 37, 38 REFER participants to their course book.

Lets take a look at Exercise 3.

Advance

The call circuit is a combination Input/Output

circuit. In the call circuit below, the call

terminal stays about 10 volts above ground

when activated. Why?


answers.

Advance

REVIEW slides


REFER participants

Course Book




In your own words:


37

PPT slide 39 REFER participants to their course book.

Solution:

Because Zener diode failure causes an

active circuit to measure close to ground

instead of 10 volts above ground. Zener

diodes are semiconductor diodes which have

been manufactured to have their reverse

breakdown occur at a specific, well-defined

voltage (its “Zener voltage”), and that are

designed such that they can be operated be

operated continuously in that breakdown

mode. Commonly available Zener diodes are

available with breakdown voltages (“Zener

voltages”) anywhere from 1.8 to 200 V. In the

MCE call circuit above, the Zener diode is a

10-volt breakdown voltage.

Advance

REVIEW slide


REFER participants

Course Book




In your own words:


38

PPT slide 40

At instructor’s discretion, take time to

visit the field and practice one or more of

the following:

• Troubleshoot hydraulic sequence of

operation

• Troubleshoot a PLC problem using

electrical diagrams

• Troubleshoot a safety circuit using

electrical diagrams

• Troubleshoot a Call Circuit using

electrical diagrams

Advance

Module Length: 300 min Time remaining: 150 min This section: 120 min Section start time: ________ Section End Time: ________

ASK

CLASSROOM

ACTIVITY




In your own words:


39

PPT slides 41, 42 Read slide.

For each objective, briefly review what

was learned in this module or ask

participants to share what they have

learned for each learning objective and

briefly discuss as a class.

Advance

Lets take a look at some of the key words we

have defined as moved through this module.

Read slide. Discuss definitions as a

group.

Advance


CLASSROOM

ACTIVITY




In your own words:


40

PPT slides 43

Administer quizzes.


CLASSROOM

ACTIVITY Quizzes

Pencils

INDIVIDUAL ACTIVITY

instructor guide - transit training network · 2017. 1. 30. · elevator-escalator –...

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