Skill 2: Test A Manual Switch

SKILL 2 TEST A MANUAL SWITCH
Procedure Overview
In this procedure, you will test the operation of a pushbutton switch and a
selector switch. To do this, you will insert faults into each component using the
FaultPro Computer-Based Fault Insertion Software.
 1. Perform a lockout/tagout on the main power circuit breaker of the 990-MC1F

shown in figure 2-1.
 Even though you will not be connecting any circuits in this skill, it is always
a good safety practice to lockout/tagout the power source.
Figure 2-1. 990-MC1F Portable Motor Control Troubleshooting System
L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-1

Copyright © 2015 Amatrol, Inc.
 2. Make sure a USB cable is connected between the 990-MC1F and the PC
running the FaultPro software, as shown in figure 2-2.
USB CABLE
Figure 2-2. USB Cable Connected between 990-MC1F and PC

 3. Perform the following substeps to test the N.O. contacts of pushbutton PB1
in an out-of-circuit test.
A. Locate your multimeter and set it to measure resistance.
B. Make sure that no leads are connected to the plug-in jacks on the front
panel of the 990-MC1F. If there are, disconnect them.

C. Place the multimeter leads into the terminals of the N.O. contacts of PB1,
as shown in figure 2-3, and record the measurement.
PB1 Resistance (not pressed) ____________________________ (Ohms)
If the pushbutton is good, the resistance should be infinite (open). This is
the first step of testing the pushbutton. The next step is to test it when the
operator is pressed.
N.O.
CONTACT
N.C.
CONTACT
AMPROBE 30XR-A
NON
MIN MAX CONTACT HOLD
VOLTAGE
V 600 OFF 600 V

200 200
20 20
2 2
200m 200m
200
20M 2m
2M 20m
200k 200m
20k 10 A
2k 10 A
200 200m
A
1.5V 9V
2m 20m
BATT 200
BATT 1.5V CAT 600V
mA A CAT 300V
BATT 9V
COM V
200mA
MAX
10A FUSED
MAX
10A MAX 600V
FUSED 600V
Figure 2-3. Pushbutton PB1 N.O. Contacts Out-of-Circuit Test

D. Press and hold the pushbutton and then record the resistance.
PB1 Resistance (pressed) _______________________________ (Ohms)
If the pushbutton is good, the resistance should be at or near zero. This
shows that the contacts are closing when the operator is pressed. This
pushbutton is good.
On a machine, these measurements are made by placing the multimeter
leads on the pushbutton’s N.O. contact block, similar to figure 2-4.
NOTE
The contact blocks for the pushbutton switches and the selector switch
simply snap into place. This makes them easy to replace when necessary.
N.O. CONTACT
BLOCK
Ω COM
Figure 2-4. Actual Measurement of Contacts

 4. Perform the following substeps to insert a fault into PB1 in the single fault
mode and test it.
A. Turn on the computer and login to Windows.
B. Start the FaultPro Student software.
You should open the student version of the software by double-clicking
the icon shown in figure 2-5.
Figure 2-5. Fault Pro Student Icon
The FaultPro Student login screen should appear, similar to figure 2-6.
Figure 2-6. FaultPro Student Login Screen

C. Enter your Student ID number and password (if applicable) in the fields
provided and then click the OK button or press Enter on the keyboard.
Your student ID number and password will be assigned by your instructor.
If you do not have them yet, notify your instructor.
Once your ID and password have been entered, the Student Options screen
will open, as shown in figure 2-7.
CLASS
SINGLE FAULT
FOLDER
MODE BUTTON
RANDOM FAULT
MODE BUTTON
Figure 2-7. Student Options Screen
Notice that there are two buttons available at the upper right hand side of
the Student Options Screen: Single Fault Mode and Random Fault Mode.
The single fault mode is what you are going to use in this skill. The single
fault mode allows you to manually key in a specific fault. This mode is
used when you are learning how to test an individual component. The
single fault mode can also show the results at a system level.
The random fault mode inserts unknown faults randomly from a pool of
faults that is predetermined by the instructor. You then troubleshoot the
circuit to determine which fault exists. This mode will be used in the next
LAP to troubleshoot entire circuits.
D. If necessary, open the Class folder by clicking the + to the left at the Class
name.
E. Open the LAP 2: Systems Troubleshooting option.
F. Select any skill listed.
To enter the Single Fault Mode, you need to select any skill from the list.
LAP 1 does not have any troubleshooting skills, therefore, those skills are
not listed. You do not have to select the skill you are currently performing
to start the Single Fault Mode.

G. Click the Single Fault Mode button.

The FaultPro software will open the Single Fault Mode window, shown in
figure 2-8.
Figure 2-8. Single Fault Mode Dialog
H. Type 36 in the Enter Fault field.

I. Press the Enter key or click to activate the fault.
Fault 36 is now active. You should observe that the fault status field
changes from “No Faults Active” to “Fault 36 is Active.”
Fault 36 is a short in the N.O. contacts of PB1.
J. Repeat step 3 to test the pushbutton and record your measurements.
PB1 Resistance (not pressed) ___________________________ (Ohms)
PB1 Resistance (pressed) _______________________________ (Ohms)
Component Status _________________________________ (Good/Bad)

This time you should find that the multimeter measures zero resistance
in both conditions. This means that there is a short in the contacts. The
component is bad.
K. Click the Clear Fault button to clear the fault.
With the FaultPro software, the fault will clear and the fault status field
should change to “Fault 36 is cleared.”
L. Repeat the pushbutton test in step 3.
PB1 Resistance (pressed) ______________________________ (Ohms)

The resistance should change this time when the pushbutton is pressed.
This means it is good again.

 5. Perform the following substeps to test an open type fault in N.O. contacts.
A. Type 37 to insert fault 37 in the Enter Fault field.
B. Press the Enter key or click on the to activate the fault.
Fault 37 is now active. You should observe that the fault status field
changes from “Fault 37 is cleared” to “Fault 37 is Active.”
Fault 7 is an open in the N.O. contacts of PB1.
C. Repeat step 3 to test the pushbutton and record your measurements.
PB1 Resistance (pressed) ______________________________ (Ohms)
This time you should find that the multimeter measures infinite resistance
in both conditions. This means that there is an open in the contacts. The
component is bad.
D. Click the Clear Fault button to clear the fault or remove the fault plug.
With the FaultPro software, the fault will clear and the fault status field
should change to “Fault 37 is cleared.”
 6. Now test the N.C. contacts of PB2. Use the same out-of-circuit test procedure
as in step 3, except measure at the N.C. contact jacks of PB2. Record your
results.
PB2 Resistance (not pressed) ______________________________ (Ohms)
PB2 Resistance (pressed) _________________________________ (Ohms)
Component Status ___________________________________ (Good/Bad)

 These contacts should be good. This is indicated by zero resistance when not
pressed and infinite resistance when pressed. This is the opposite result of the
N.O. contacts.

 Again, this is the same as measuring the resistance at the pushbutton’s N.C.
contact block, similar to figure 2-9.
N.C. CONTACT
BLOCK
Ω COM

 7. Type 24 in the Enter Fault field and press the Enter key or click to activate
the fault.
 Fault 24 is now active. This will cause a short in the N.C. contacts of PB2.
This condition can occur if the contacts are welded together by high current
draw.

 8. Now test the N.C. contacts of PB2. Use the same out-of-circuit test procedure
as you did in step 6. Record your results.

 The resistance should be zero in both conditions. This indicates that the
switch is bad.
NOTE
It is necessary to test the switch when actuated and not actuated. If you just
checked this contact in the unactuated state, you might assume in error that the
contacts are good.
 9. Click the Clear Fault button to clear the fault.

 The fault will clear and the fault status field should change to “Fault 24 is
cleared.”
 10. Repeat step 8 again to test the contacts.

 You should find that the contacts are now operating normally again.
 So far, you have faulted N.C. contacts to the shorted condition only. It is
important to note that these contacts can also fail in the open condition. In a
similar manner, N.O. contacts can fail either open or closed. In the next steps
in this skill, you test these conditions.
 11. Use your new skills to test the N.C. contacts of PB3 using the out-of-circuit
test procedures. Record your results.

 The contact should be good. This means the resistance should be zero when
not pressed and infinite when pressed.

 12. Type 34 in the Enter Fault field and press the Enter key or click to activate
the fault.
 Fault 34 is now active. This will cause an open in the N.C. contacts of PB3.
This condition can occur if the contacts are mechanically broken or have be
burned open by excessive current.
 13. Test the N.C. contacts of PB3 again. Record your results.

 You should find that the contacts are now bad because the resistance reads
infinite in both conditions.
 14. Click the Clear Fault button to clear the fault.
 The fault will clear and the fault status field should change to “Fault 34 is
cleared.”
 15. Now test the N.C. contacts of PB3. Record your results.
Component Status ____________________________________ (Good/Bad)

 The contacts should be good. This means the resistance should be zero when
not pressed and infinite when pressed.
 The faults you have seen so far in this skill involved pushbuttons. These same
types of faults can also occur in selector switches. In the remaining steps of
this skill, you will test a selector switch.

 16. Perform the following substeps to test the upper set of contacts of selector
switch SS1 using the out-of-circuit test procedures.
A. Rotate the selector switch SS1 operator to the center position.
In this position, the upper contacts of this switch should be open.
B. Place the multimeter leads into the terminals of the left (upper) contacts of
SS1 and record the measurement.
SS1 Resistance (operator in center) ______________________ (Ohms)
If the contacts are good, the resistance should be infinite (open). This is
the first step of testing the selector switch. The next step is to test it when
the operator is switched.
Again, this relates to measuring at the contact block, similar to figure
2-10.
N.O. CONTACT
BLOCK
Ω COM
C. Rotate the selector switch to the left position and record the resistance.
SS1 Resistance (operator in left) ________________________ (Ohms)
If the contacts are good, the resistance should be at or near zero. This
shows that the contacts are closing when the operator is switched. This
selector switch should be good.

 17. Perform the following substeps to insert a fault into SS1 and test it using an
out-of-circuit test.
A. Type 30 in the Enter Fault field.
B. Press the Enter key or click to activate the fault.
Fault 30 is an open in the upper contacts of SS1.
C. Test the selector switch and record your results.
SS1 Resistance (operator in center) ______________________ (Ohms)
SS1 Resistance (operator in left) ________________________ (Ohms)

This time you should find that the multimeter measures infinite resistance
in both conditions. This means that there is an open in the contacts. The
component is bad.
D. Click the Clear Fault button to clear the fault.
 18. Click Exit to exit the single fault mode and return to the Student Options
window.
 19. Perform the following substeps to shut down the troubleshooting system.
A. Click the Logout button and then click the Exit button to exit the FaultPro
software.
B. If this is your last activity for the day, return the lockout/tagout equipment
to your instructor. If not, continue.


Skill 2: Test A Manual Switch

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SKILL 2 TEST A MANUAL SWITCH

 1. Perform a lockout/tagout on the main power circuit breaker of the 990-MC1F

Figure 2-1. 990-MC1F Portable Motor Control Troubleshooting System

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-1

Figure 2-2. USB Cable Connected between 990-MC1F and PC

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-2

V 600 OFF 600 V

Figure 2-3. Pushbutton PB1 N.O. Contacts Out-of-Circuit Test

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-3

Figure 2-4. Actual Measurement of Contacts

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-4

Figure 2-5. Fault Pro Student Icon

Figure 2-6. FaultPro Student Login Screen

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-5

Figure 2-7. Student Options Screen

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-6

G. Click the Single Fault Mode button.

Figure 2-8. Single Fault Mode Dialog

H. Type 36 in the Enter Fault field.

PB1 Resistance (pressed) _______________________________ (Ohms)

Component Status _________________________________ (Good/Bad)

PB1 Resistance (pressed) ______________________________ (Ohms)

Component Status _________________________________ (Good/Bad)

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-7

Component Status ___________________________________ (Good/Bad)

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-8

Figure 2-9. Actual Measurement of Contacts

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-9

PB2 Resistance (pressed) _________________________________ (Ohms)

Component Status ___________________________________ (Good/Bad)

 9. Click the Clear Fault button to clear the fault.

PB2 Resistance (pressed) _________________________________ (Ohms)

Component Status ___________________________________ (Good/Bad)

PB3 Resistance (pressed) _________________________________ (Ohms)

Component Status ___________________________________ (Good/Bad)

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-10

PB3 Resistance (pressed) _________________________________ (Ohms)

Component Status ___________________________________ (Good/Bad)

PB3 Resistance (pressed) _________________________________ (Ohms)

Component Status ____________________________________ (Good/Bad)

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-11

Figure 2-10. Actual Measurement of Contacts

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-12

SS1 Resistance (operator in left) ________________________ (Ohms)

Component Status _________________________________ (Good/Bad)

L11152-AB01UEN-E1-S02, REV. A INTRODUCTION TO TROUBLESHOOTING S02-13

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