M17 Find and Repair Faults in Measuring and Analysis System V2

Mechatronics and Instrumentation
Servicing Management
Level IV
Based on May, 2011 Version 1 Occupational
Standards
Module Title: Find and repair faults in measuring

and analysis systems
LG Code: EEL MIS4 LO (1-3) LG# (66-68)
TTLM Code: EEL MIS4 TTLM 1220v1
December 2021
Bishoftu Ethiopia
Contents
LG #66...............................................................................................................................3
Page 1 of 120 Federal TVET Agency TVET program title : Mechatronics and Instrument Version -1
Author/Copyright Servicing Management level IV February 2021
LO #1 Prepare to find and repair faults........................................................................3
Instruction sheet................................................................................................................3
Information Sheet 1........................................................................................................5
Self-Check1.....................................................................................................................12
Operation Sheet #1.........................................................................................................13
Prepare to find and repair faults......................................................................................13
LAP TEST #1...................................................................................................................14
Information Sheet 2......................................................................................................15
Self-Check 2....................................................................................................................20
Information sheet 3.......................................................................................................22
Causes of Faults...........................................................................................................22
Nature of Faults............................................................................................................23
1) Symmetrical Fault.................................................................................................24
2) Unsymmetrical Fault.............................................................................................24
Transient Fault..........................................................................................................26
Permanent Fault........................................................................................................27
Effect of Faults..............................................................................................................27
Self-Check 3....................................................................................................................27
Operation Sheet #2.........................................................................................................29
LAP TEST #2...................................................................................................................30
Electrical Engineering Consultant Responsibilities.........................................................32
Electronics/Electrical Supervisor.....................................................................................33
When to Advice............................................................................................................34
Self-Check 4....................................................................................................................35
Self-Check 5....................................................................................................................38
Operation Sheet #3.........................................................................................................39
LAP TEST #3...................................................................................................................40
Millimeter......................................................................................................................43
Soldering Station..........................................................................................................43
Needle-nose Pliers and Wire Cutter.............................................................................45
Figure 6.5. Needle-nose Pliers and Wire Cutter..........................................................45
Jumper Wires............................................................................................................46
Varied Sensors and Modules....................................................................................47
Arduino Starter Kit........................................................................................................47
Cabinet organizer.........................................................................................................48
Self-Check 6....................................................................................................................48
A) Arduino Starter Kit B) Multimeter..........................................49
LG #.................................................................................................................................50
Lo #2- Find and Repair Faults.......................................................................................50
Instruction sheet..............................................................................................................50
Information sheet 1:......................................................................................................53
Self check:1.....................................................................................................................55
Self check:1....................................................................................................................57
Self check:1.....................................................................................................................65
Importance of fault finding.....................................................................................67
Self check:1.....................................................................................................................69
Operation Sheet #1........................................................................................................71
Find and Repair Faults..................................................................................................71
LAP TEST #1...................................................................................................................72
Self check:1.....................................................................................................................76
Operation Sheet #1........................................................................................................79
Find and Repair Faults..................................................................................................79
LAP TEST #1...................................................................................................................80
Safety Information......................................................................................................81
Self check:1.....................................................................................................................83
Information sheet 8......................................................................................................84
If there is no warranty or the warranty has expired............................................85
Self check:1.....................................................................................................................86
Profession mechatronics assembler..................................................................................86
Personality Type............................................................................................................86
Knowledge....................................................................................................................87
Self-Check 9....................................................................................................................90
Operation Sheet #1..........................................................................................................90
Find and repair faults.......................................................................................................90
Lap Test #1......................................................................................................................92
Information Sheet 10....................................................................................................92
Description....................................................................................................................92
Self-Check 10..................................................................................................................93
BASIC STEPS IN FAULT FINDING IN ELECTRONICS.................................................94
Self-Check 11..................................................................................................................96
Operation Sheet #2..........................................................................................................97
Find and repair faults.......................................................................................................97
Lap Test #2......................................................................................................................98
LG #56.............................................................................................................................99
LO #3 Completion and report fault finding and repair activities....................................99
Instruction sheet............................................................................................................100
Self-Check1...................................................................................................................104
Guidance for Cleaning and Disinfecting of Electrical Equipment..................................112
What to do:.................................................................................................................113
What not to do:...........................................................................................................113
Self-Check 2..................................................................................................................115
1. List and Explain Guidance for Cleaning and Disinfecting of Electrical Equipment (5)?116
Hydraulic Repair.............................................................................................................117
PSI Hydraulic Repair Services Include:.....................................................................118
Self-Check 3.................................................................................................................118
Information Sheet 4.....................................................................................................120
Self-Check 4.................................................................................................................122
Reference......................................................................................................................124
ACKNOWLEDGEMENT................................................................................................125
The trainers who developed the TTLM..........................................................................125
Information Sheet 1 Identify and understanding of OH&S procedures
Introduction
An internationally acknowledged requirement is to analyze and provide technical solutions for
prevention and safety during the use and maintenance of Mechatronics equipments. Injuries statistics
data and Speciﬁc studies show that particular constructive criticalities have been identiﬁed on these
Equipments, which are the cause of serious and often fatal accidents. These accidents particularly
occur during the washing and maintenance phases, especially when such practices are carried out
inside the hopper when the rotating parts of the machine are in action. The current technical
standards and the Various safety requirements under consideration have not always been effective
for protecting workers. To this end, the use of SWOT analysis (Strengths, Weaknesses,
Opportunities, and Threats) allowed us to highlight critical and positive aspects of the different
solutions studied for reducing the risk due to contact with the rotating parts.
 Personal protective equipment for Mechatronics

 Safety hat
 Safety shoes
 Mask
 Safety goggles
 Hand gloves
 Safety Hat
In many industrial working environments, for example, mining, power, construction, and forestry, the
risk of head injury to workers is constantly present. The most serious risks are physical injuries, which
can be as a result of the impact of a falling object or collision with fixed objects at the workplace. Due
to the nature of these work activities, it is not always possible to eliminate such risks with just
appropriate organizational solutions or collective protective equipment. Therefore, the only way to
ensure the safety of workers is by using safety helmets. The type of helmet will depend on the
specific nature of the physical risks that have been identified in the risk assessment undertaken for
the activity. This article provides information for users of protective helmets as well as employers and
OSH engineers. It includes information on definitions and gives the requirements for different kind of
protective helmets that offer protection against physical risks [1].
Figure 1.1. Mechatronics safety hat

 Safety shoes
When you think about shoes for the workplace, heavy-duty footwear such as steel toe boots may
come to mind. These boots, which have reinforced toes to protect the feet from hazards such as
heavy objects, are important personal protective equipment (PPE) at many industrial and
construction worksites. Many kinds of shoes exist that can make jobs safer, though, not just steel toe
boots. Other types of boots and shoes can provide traction, arch support and other safety benefits. To
find the right foot protection for the jobs in your workplace, you’ll need to do a hazard assessment and
determine what kinds of risks such as slipping and falling or sharp objects pose a threat to your
employees’ feet. Then select shoes or boots that offer the right protection. Shoes may not seem as
critical to workplace safety as protective eyewear or gloves, but footwear provides many benefits. If
anyone in your workplace doubts the value of investing in footwear, offer him or her some of the ways
safety shoes can keep workers safe [2].
 Purpose of safety shoes
 protect from falling & flying objects
 protect from punctures
 protect from cutting hazards
 protect from electrical hazards
 prevent slips, trips & falls
 prevent fatigue
 protect from extreme weather
 prevent burn
Figure 1.2. Safety Shoes

 Mask
Industry workers use Repaired Product Products in their work which contains chemicals that may
be harmful to their health. These chemicals can enter the body in various ways: breathing in the
chemicals or dust from the Repaired Product Products they use; direct contact with the chemicals or
Repaired Product Product dust via skin and/or eyes; or accidentally ingesting the chemicals or dust.
However, there are many ways workers can protect themselves.
Air Purifying Respirators are the only masks that will protect against chemical gases and vapors. The
type of cartridge the mask uses can vary, depending on what type of chemical is being used in the
salon. In order to use this style of mask, the salon owner and/or manager should develop a
respiratory protection program. This should include getting each worker fitted and trained on how to
use this mask, as well as identifying which cartridge(s) their employees should use [3].
Figure 1.3.Air Purifying Respiratory Mask
 Safety goggles
If a worker is suffering from an eye injury, it’s most likely due to improper eye protection or lack of any
eye protection at all. Many people do not realize the importance of eye protection in the workplace.
Potential hazards can be avoided simply by covering your eyes. Here are the top five reasons why
you need to wear safety glasses.
 Safety glasses can prevent foreign objects that are floating around from damaging your
vision. Dangerous particles or chemicals could be floating around in your workplace. Some
jobs that are at a high risk include construction, maintenance, welding, plumbing, and mining.
Dirt, dust, pollen, and wood can irritate your eyes and potentially cause long lasting damage.
 Avoid major accidents. Shield your eyes from splashes of chemicals, grease or oil, fumes,
burns, and flying wood chips. Wiping substances into your eyes, sometimes without noticing,
can easily scratch them. You can have recurring, long-term problems, including blindness,
from only a minor injury.
 UV light protection. Working long hours outside with UV light exposure can affect the fragile
tissues in the eye. Many exposed workers don’t realize the importance of a regular visit to the
eye doctor; an eye exam could relay diseases like multiple sclerosis or even cancer.
 Computer Vision Syndrome. Wearing safety glasses can also prevent Computer Vision
Syndrome. CVS is the result of viewing a computer screen for long periods of time. Workers
can develop eyestrain, blurred vision, and dry eyes. You may not realize that the poor lighting
or glare on the computer screen is causing these symptoms. Wearing safety glasses with
coated lenses will help to keep away the discomfort and blurred vision.
 Fashionable Eyewear. You may not feel comfortable wearing different glasses but there are
plenty of stylish safety glasses to choose from. The safety glasses are designed to fit your
specific needs for your work environment. You can have colored frames, tinted lenses, wrap
around glasses, removable foam and more. Some of them even allow you to insert your
prescription lenses. Don’t rely on your own sunglasses or prescription glasses to protect your
eyes from harm. Wearing properly designed safety glasses will help prevent all potential
hazards.
Figure 1.4. Safety Glasses

 Hand gloves
If there is one thing more important than ensuring workers are wearing safety gloves, it is ensuring
workers are wearing the correct safety gloves for the specific industry and tasks they perform on the
job. Wearing the wrong safety gloves won’t protect the wearer from all the potential hazards in their
environment. There are some considerations that need to be made when choosing safety gloves.
Figure 1.5. Hand Gloves
The following injuries can be avoided by selecting the correct safety gloves for the handling
application, and ensuring that these safety gloves are worn at the right times:
 Puncture wounds
 Cuts and scrapes
 Heat and chemical burns
 Hazardous substances that can irritate or be absorbed by the skin
 Extreme heat or cold
 Biological agents like bacteria and viruses
 Loss of finger, nail and skin
 Needle stick injuries
 Identify the hazards

Identifying hazards involves finding all of the tasks, situations and sequences of events that could
potentially cause harm. Hazards arising from electrical equipment or installations may arise from:
„ the design, construction, installation, maintenance and testing of electrical equipment or electrical
installations „ design change or modification „ inadequate or inactive electrical protection" where and
how electrical equipment is used. Electrical equipment may be subject to operating conditions that
are likely to result in damage to the equipment or a reduction in its expected life span. For example,
equipment may be at greater risk of damage if used outdoors or in a factory or workshop environment
„ electrical equipment being used in an area in which the atmosphere presents a risk to health and
safety from fire or explosion, for example confined spaces „ type of electrical equipment. For
example, ‘plug in’ electrical equipment that may be moved around from site to site, including
extension leads, are particularly liable to damage „ the age of electrical equipment and electrical
installations „ work carried out on or near electrical equipment or electrical installations, including
electric overhead lines or underground electric services, for example work carried out in a confined
space connected to plant or services. Exposure to high electromagnetic fields may also present a
potential hazard for workers with some medical conditions, for example pace makers. You must
inform workers and other persons at the workplace of any potential electromagnetic hazards at the
workplace that may affect a medical condition. You must also manage risks to health and safety
arising out of electromagnetic hazards, including eliminating the risk so far as is reasonably
practicable. If that is not reasonably practicable you must minimize the risk so far as is reasonably
practicable. Potential electrical hazards may be identified in a number of different ways including:
„ talking to workers and observing where and how electrical equipment is used „ regularly inspecting
and testing electrical equipment and electrical installations as appropriate „ reading Repaired Product
Product labels and manufacturers’ instruction manuals „ talking to manufacturers, suppliers, industry
associations, and health and safety specialists „ reviewing incident reports.
Self-Check1
Written Test
Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
1. How to Identify hazards in the work place ? (1 point each)
2. One of the following is not Personal protective equipment for Mechatronics (1 point each)
A) Safety hat B)Safety shoes
C) Mask D) None
3. Define the following terms (1 point each)
1. Biological agents
2. Extreme heat or cold
3. Hand Gloves
4. Mask
5. Safety shoes
6. PPE
7. OHS
8. Eye Glasses
Note: Satisfactory rating 10 points Unsatisfactory - below 10

You can ask you teacher for the copy of the correct answers.
Score___________
Rating___________
Identifying and Understanding of OH&S
Operation Sheet #1 procedures
 Operation Title: - Identifying and Understanding of OH&S procedures

PURPOSE: -
o The trainee’s will be able to keep the procedures.
o The trainee’s will be able to prepare to find and repair faults.
o The trainee’s will be able to perform Identifying and understanding of OHS procedures
for finding fault.
Conditions or situations for operation: - Have a clean workspace with all necessary tools and
equipment.
Equipment, Tools & Materials: - Maintenance room, Hand gloves, Eye goggles, Hat,
Procedure: - 1. Check/Inspect Maintained/ assemble Repaired Product
 Step 1: Clean working area.
 Step 2: Identify PPE used for Mechatronics Equipment maintenance.
 Step 3: Prepare PPE used for Mechatronics Equipment maintenance..
Precautions:-
 Take ESD precautions.
 Document everything .
 Power all devices and disconnect them from the main power supply.
Quality Criteria:-
 The trainee’s use safety for documents &components.
 The trainee’s make Identify and understand OHS procedures for finding fault and repair.
LAP TEST #1
Practical Demonstration
Name: ____________________________________ Date: ________________________

Time started: _____________________________Time finished: __________________
Instructions: You are required to perform the following individually with the presence of your
teacher.
Task 1
1. Identifying and Understanding of OH&S procedures
2. From General safety precautions show the antistatic:
 Electrostatic wrist strip
 Antistatic mat
 Antistatic box
 Your teacher will evaluate your output either satisfactory or unsatisfactory. If
Unsatisfactory, your teacher shall advice you on additional work. But if satisfactory, you can
proceed to the next topic
Information Sheet 2 Following OH&S risk control measures and procedures
The main ways to control a hazard during preparations of work include:

 Elimination (including substitution): remove the hazard from the workplace, or substitute
(replace) hazardous materials or machines with less hazardous ones.
 Engineering Controls: includes designs or modifications to plants, equipment, ventilation
systems, and processes that reduce the source of exposure.
 Administrative Controls: controls that alter the way the work is done, including timing of
work, policies and other rules, and work practices such as standards and operating procedures
(including training, housekeeping, and equipment maintenance, and personal hygiene
practices).
 Personal Protective Equipment: equipment worn by individuals to reduce exposure such as
contact with chemicals or exposure to noise
Controls are usually placed:
 At the source (where the hazard "comes from").
 Along the path (where the hazard "travels").
 At the worker
Elimination is the process of removing the hazard from the workplace. It is the most
Elimination
effective way to control a risk because the hazard is no longer present. It is the
preferred way to control a hazard and should be used whenever possible.
Engineering controls are methods that are built into the design of a plant,
Engineering controls
equipment or process to minimize the hazard. Engineering controls are a
very reliable way to control worker exposures as long as the controls are designed, used and
maintained properly. The basic types of engineering controls are:
 Process control.
 Enclosure and/or isolation of emission source.
 Ventilation.
PROCESS CONTROL
Process control involves changing the way a job activity or process is done to reduce the risk.
Monitoring should be done before and as well as after the change is implemented to make sure the
changes did, in fact, control the hazard.
Examples of process changes include to:
 Use wet methods rather than dry when drilling or grinding. "Wet method" means that water is
sprayed over a dusty surface to keep dust levels down or material is mixed with water to
prevent dust from being created.
 Use an appropriate vacuum or "wet method" instead of dry sweeping (e.g. with a broom) to
control dust and reduce the inhalation hazard.
 Note: Never use a regular "household" vacuum cleaner, especially when cleaning toxic
material such as lead, or asbestos. Use a vacuum specifically designed for industrial
workplaces and be sure to use appropriate filters, etc.
 Use steam cleaning instead of solvent degreasing (but be sure to evaluate the potential high
temperature hazard being introduced such as heat stress).
 Use electric motors rather than diesel ones to eliminate diesel exhaust emissions.
 Float "balls" on open-surface tanks that contain solvents (e.g. degreasing operations) to
reduce solvent surface area and to lower solvent loss.
 Instead of conventional spray painting, try to dip, paint with a brush, or use "airless" spray paint
methods. These methods will reduce the amount of paint that is released into the air.
 Decrease the temperature of a process so that less vapour is released.
 Use automation - the less workers have to handle or use the materials, the less potential there
is for exposure.
 Use electronics transportation rather than manual methods
ENCLOSURE AND I SOLATION
An enclosure keeps a selected hazard "physically" away from the worker. Enclosed equipment, for
example, is tightly sealed and it is typically only opened for cleaning or maintenance. Other examples
include "glove boxes" (where a chemical is in a ventilated and enclosed space and the employee
works with the material by using gloves that are built in), abrasive blasting cabinets, or remote control
devices. Care must be taken when the enclosure is opened for maintenance as exposure could occur
if adequate precautions are not taken. The enclosure itself must be well maintained to prevent leaks.
Isolation places the hazardous process "geographically" away from the majority of the workers.
Common isolation techniques are to create a contaminant-free or noise-free booth either around the
equipment or around the employee workstations.
VENTILATION
Ventilation is a method of control that strategically "adds" and "removes" air in the work environment.
Ventilation can remove or dilute an air contaminant if designed properly. Local exhaust ventilation is
very adaptable to almost all chemicals and operations. It removes the contaminant at the source so it
cannot disperse into the work space and it generally uses lower exhaust rates than general ventilation
(general ventilation usually exchanges air in the entire room).
Local exhaust ventilation is an effective means of controlling hazardous exposures but should be
used when other methods (such as elimination or substitution) are not possible.
A local exhaust ventilation system consists of these basic parts:
1. A hood that captures the contaminants generated in the air (at the source).
2. Ductwork (exhaust stack and/or recirculation duct) that carries the contaminated air to the air
cleaning device, if present or to the fan (away from the source).
3. A fan which draws the air from the hood into the ducts and removes the air from the
workspace. The fan must overcome all the losses due to friction, hood entry, and fittings in the
system while producing the intended flow rate.
4. Air cleaning devices may also be present that can remove contaminants such as dust
(particulates), gases and vapours from the air stream before it is discharged or exhausted into
the environment (outside air), depending on the material(s) being used in the hood.
Administrative controls limit workers' exposures by scheduling shorter
Administrative controls
work times in contaminant areas or by implementing other "rules". These
control measures have many limitations because the hazard itself is not actually removed or reduced.
Administrative controls are not generally favored because they can be difficult to implement, maintain
and are not a reliable way to reduce exposure. When necessary, methods of administrative control
include:
 Restricting access to a work area.
 Restricting the task to only those competent or qualified to perform the work.
 Scheduling maintenance and other high exposure operations for times when few workers are
present (such as evenings, weekends).
 Using job-rotation schedules that limit the amount of time an individual worker is exposed to a
substance.
 Using a work-rest schedule that limits the length of time a worker is exposure to a hazard
What are electrical risks?
Electrical risks are risks of death, electric shock or other injury caused directly or indirectly by
electricity. The most common electrical risks and causes of injury are: „ electric shock causing injury
or death. The electric shock may be received by direct or indirect contact, tracking through or across
a medium, or by arcing. For example, electric shock may result from indirect contact where a
conductive part that is not normally energized becomes energized due to a fault (e.g. metal toaster
body, fence) „ arcing, explosion or fire causing burns. The injuries are often suffered because arcing
or explosion or both occur when high fault currents are present „ electric shock from ‘step-and-touch’
potentials „ toxic gases causing illness or death. Burning and arcing associated with electrical
equipment may release various gases and contaminants „ fire resulting from an electrical fault. Even
the briefest contact with electricity at 50 volts for alternating current (V of A.C.) or 120 volts for direct
current (V d.c.) can have serious consequences to a person’s health and safety. High voltage shocks
involving more than 1000 V a.c. or 1500 V d.c. can cause contact burns and damage to internal
organs. Electric shocks from faulty electrical equipment may also lead to related injuries, including
falls from ladders, scaffolds or other elevated work platforms. Other injuries or illnesses may include
muscle spasms, palpitations, nausea, vomiting, collapse and unconsciousness. Workers using
electricity may not be the only ones at risk—faulty electrical equipment and poor electrical
installations can lead to fires that may also cause death or injury to others.
Who must manage electrical risks?
A person conducting a business or undertaking has the primary duty under the WHS Act to ensure,
so far as is reasonably practicable, that workers and other persons at the workplace are not exposed
to electrical risks arising from the business or undertaking. This duty requires eliminating electrical
risks or, if that is not reasonably practicable, minimizing the risks so far as is reasonably practicable.
The WHS Regulations include more specific requirements for managing electrical risks at the
workplace. For example, all persons conducting a business or undertaking have duties to ensure, so
far as is reasonably practicable, that electrical equipment and installations at the workplace are
without risks to health and safety of persons. Persons conducting a business or undertaking with
management or control of a workplace have a duty to ensure effective Residual Current Devices
(RCDs) are used in certain high-risk environments as defined in the regulations and explained in
more detail below. Persons conducting a business or undertaking carrying out electrical work must
comply with the prohibition on electrical work on energized electrical equipment subject to certain
exceptions. These persons may also have duties under local electrical safety laws. Persons
conducting a business or undertaking should ensure electrical installation work is carried out by
qualified persons and testing and compliance requirements are met.
Self-Check 2
Written Test
Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
1. Part I Choose The best answer (each 2 points)
1. _____________are risks of death, electric shock or other injury caused directly or indirectly by
electricity..
A) Electrical Risk B) Hand tools
C) Equipment D) All
2. Using a work-rest schedule that limits the length of time a worker is exposure to a hazard
A) Process Control B) Administrative control
C) Ventilations D) None
3.____________ is a method of control that strategically "adds" and "removes" air in the work
environment.
A) Ventilations B) Biological agents
C) Loss of finger, nail and skin D) All
Part II Explain the following terms (each three points)
1. Process Control
2. Electrical risk
3. Electrical risk managements
4. Administrative control
Note: Satisfactory rating 10 Unsatisfactory - 10
Score___________
Rating___________
Information sheet 3 Obtaining the Nature of Faults from Documentation
Cause, Nature of Fault and Effect of fault

A fault occurs due to the failure of the insulation of a conductor at one or more point or a conducting
object comes in contact with the live part of the system. The transmission line is most prone to faults.
If the conductors of line come in contact with each other or with the ground [6].
There is a number of causes for the occurrence of a fault in the power system.
Causes of Faults
Some of the possible causes of faults are,
 Overvoltage due to switching surges
 Severe lightning strokes
 Aging of conductor
 Heavy wind, rains, and snowfall
 Falling trees on the transmission line
 Excessive internal and external stresses on the conductors
 High changes in atmospheric temperatures
 Accident of vehicle with towers or poles of transmission line
 Perching of birds on the lines
 Accidental short circuit due to string, snakes
 Chemical pollution
There is always the possibility of occurrence of a fault in the power system. Therefore, it is necessary
to protect the costly equipment. Most of the area of power system network is covered by
the transmission lines and it placed in the open air. Hence, due to atmospheric conditions, the
maximum possibility of fault occurrence is on transmission lines. Most of the faults lead to short circuit
condition and because of this, the impedance of the short circuit path becomes very low and very
large fault currents flow. Thus, it is important to evaluate these fault currents under short circuit
conditions. And according to this, design and select the protective equipment.
Table 3.1. Fault distributions in various part of system
Sr. No. Equipment % of the total fault
1 Overhead lines 50
2 Switch gear 15
3 Transformer 12
4 Cables 10
5 Miscellaneous 8
6 Control Equipment 3
7 CT and PT 2
Nature of Faults
The faults are classified as,
 Symmetric Fault
 Unsymmetrical Fault
1) SYMMETRICAL FAULT
When all three conductors of the three-phase system are brought together into a short circuit, the
fault is a symmetrical fault. It means in symmetrical fault; all three conductors are affected by the
fault. This gives rise to heavy fault current in all the lines. If there is a breakdown in insulation
between all conductors, this type of fault will occur. It is also known as LLL fault. The fault current will
remain symmetrical. LLL and LLLG faults are included in the symmetrical fault. These faults are rarely
occurring in practice but it is very severe in nature.
FIGURE 3.1. A) T HREE PHASE TO EARTH (LLLG) B) T HREE PHASE (LLL)
2) UNSYMMETRICAL FAULT
The fault which gives unsymmetrical current in the three lines and makes unequal displacement of
current is known as an unsymmetrical fault.
Figure 3.1. A) Single-phase to earth (L-G fault) B) phase to phase fault (L-L) C) two phase to earth (L-
L-G) fault
There are various types of unsymmetrical faults that occur in the power system network. These are
categorized below.
Single-Line to Ground Fault
This type of fault occurs when one phase is short-circuited with the ground. This is the most
commonly occurring fault.
Double-line to Ground Fault
This type of fault occurs when two phases are short-circuited with the ground. This fault occurs due to
insulation breakdown between phases and ground.
Line to Line Fault
In this fault, two conductors are short-circuited with each other.
Open circuit fault
Due to an accident, there is an open circuit in the lines due to the breaking of lines. This fault creates
an unbalanced current to flow in the system.
Table 2.2. The percentage occurrence of different types of faults.
Sr. No. Type of Fault % occurrence
1 Line to Ground (L-G) 85
2 Double Line to Ground (L-L-G) 5
3 Line to Line (L-L) 8
4 L-L-L or L-L-L-G >2
According to nature, the faults are classified as,

 Transient Fault
 Permanent Fault.
TRANSIENT FAULT
Most of the faults are transient in nature. These faults remain for a short duration of time. For
example, if a twig falls across a line and across the arm and burns itself or falls down, then the fault is
transient. It will vanish after a few cycles. In this type of fault, the fault current is high for 3-4 cycles
but it decreases rapidly in the next cycles. This zone in which the current is very high but decreases
very rapidly is known as ‘sun-transient.’ After that, for a few cycles, the fault current decreases slowly,
this region is known as ‘transient’. This state remains for a few cycles.
After the transient state is over, a steady-state is reached. The RMS value of short-circuit current
remains constant during the steady-state. The circuit breaker operates during a transient state.
PERMANENT FAULT
In this type of fault, the fault is permanent. For example, the insulation of two conductors are failed
and due to this short-circuit occurs in the system. These faults will not vanish itself. This fault needs to
do some maintenance and required more time to solve the fault. This type of fault occurs rarely.
The various effect of faults in the power system are,
Effect of Faults
 The fault set up very heavy fault current which is very large in magnitude.
The fault current can damage the equipment used in the power system network.
 A high amount of fault current produces heat which causes the overheating and electronics
stress in the conductors.
 There is always a danger of fire due to arcing caused by heavy currents. If the fault persists for
a long time then the fire may spread to other parts of the system.
 The overheating causes weakening of the insulation of conductors which reduces the life of
insulation.
 The unbalanced current and voltage can cause the heating of rotating machines connected to
the system.
 The generators are interconnected. It must be operated in synchronism. Due to unbalance in
current and voltages, generators may lose their synchronism. Which causes the total shutdown
of the system and in the worst condition it will lead to the blackout. Thus, the fault affects system
stability.
 There may be an interruption in the supply to the consumers thus reducing the reliability of the
system
Self-Check 3
Written Test
1. __________is type of fault occur when, two conductors are short-circuited with each other.
A) Line of sight fault B) Transient fault
C) A and B D) All
2. one of the following is type of fault occurs when two phases are short-circuited with the ground.
A) Double-line to Ground Fault B) single line to ground
B) Line of sight fault D) None
3. One of the following is not classified as nature of fault;
A) Symmetric fault B) Asymmetric fault
C) Line of sight fault D) All
1. Nature of electric fault
2. Cause of electric faults
3. Effect of electric Faults
4. Permanent Faults
Score___________
Rating___________
Operation Sheet #2 Prepare to find and repair faults
 Operation Title: - Obtain Nature of fault

PURPOSE: -
o The trainee’s will be able to identify cause, effect and nature of fault.
o The trainee’s will be able to Obtain electric Fault.
equipment.
Equipment, Tools & Materials: - Maintenance room, Note book, Millimeter, Screw Driver, Test light.
Procedure: - 1. Check/Inspect Maintained/ assemble Repaired Product Product
 Step 1: Clean working area.
 Step 2: Gather Information.
 Step 3: Understand the malfunction and the role the malfunctioning equipment
plays within the entire process.
 Step 4: Identify what can be measured so that you can identify items that are
outside the acceptable range.
 Step 5:Identify the source of the problem using available data and analytical tools
to isolate the defective component
 Step 6: Correct/repair the damaged component
 Step 7: Verify the repair after completion.
 Step 8: Perform root cause analysis to determine what really caused the
problem.
Precautions:-
 Discharge your equipment before finding faults.
Quality Criteria:-
 The trainee’s make Obtain the fault and repairs.
LAP TEST #2
Name: ____________________________________ Date: ________________________

teacher.
1. How to determine electric faults?

2. Explain cause and effects of electric faults?
 Antistatic mat
 Antistatic box
 Your teacher will evaluate your output either satisfactory or unsatisfactory. If Unsatisfactory,
your teacher shall advice you on additional work. But if satisfactory, you can proceed to the
next topic
Information Sheet 4 Seeking advice from work Supervisors
Introduction
An Electrical Engineering consultant usually works with a consulting firm or an electric company. You
oversee electrical projects from their design to implementation and advise the companies on proper
solutions for each project. Your responsibilities as an electrical engineering consultant are to conduct
analysis on the design of an electrical system in a commercial or residential building and suggest
solutions or possible improvements. You may coordinate the installation of new systems and consult
with organizations on potential safety issues. Your job duties require traveling to job sites to meet with
clients and carry out their projects.
Electrical Engineering Consultant Responsibilities
The electrical engineering consultant is the one who takes care of the area of control and systems
and leads the company plants. This has to be done efficiently by him. He is responsible for being
technically involved with work motors, operation controllers, and combustion controllers. He works as
a coordinator and administrator for the electrical and civil workers. He organizes the fields and is
expected to use his electrical engineering consultant knowledge and skills in the execution of his
plans.
He uses many methods that include his knowledge and skills to execute these plans. The electrical
engineering consultant responsibilities also include managing and handling other sectors of electrical
engineering department, developing policies and strategies for controlling the electrical systems
properly, and completing other tough and challenging projects.
The electrical engineering consultant recognizes the technical problems and analyzes them. He
solves the same by working on the electrical systems, design, and automation. He repairs the defects
of the electrical equipments, heads the technical department, and assists the workers under him in
completing support activities that benefit the electrical engineering department. He has the following
key responsibilities:
 Administering and directing the entire development and research activities connected to
control technology
 Creating electrical control engineering systems
 Providing training to the technical staff under him and assisting them with certain projects
 Introducing the locations of the plants to resolve power, and planning matters and automation
related to electricity
 Installing electrical engineering control systems for testing and checking, so that they can be
utilized by the customers
 Holding back various electrical engineering systems and ensure their proper functioning
 Utilizing control systems and electrical engineering equipments for operations
 Communicating with the vendors of the equipments to resolve matters on the figure, status,
and choice of the equipments
 Adhering to all the electrical system problems and coming out with their solutions
 Providing electrical engineering knowledge and wisdom to the engineers who are new or less
experienced
 Providing directions for power equipments and distribution systems
 Providing technical knowledge to figures that have a concept or purpose
 Aiding the business electrical standard team members
 Putting forth safety practices to electrical equipments like generators, transformers, inverters,
and switchgears
 Enhancing electrical technology and maintaining safety procedures in the countries of Asia
Pacific
Electronics/Electrical Supervisor
Our client has an exciting opportunity for Electrical and Electronics Supervisors to join their team. The
successful candidates will lead teams of technician's and sub-contractors on a daily basis, motivating
and delegating work to ensure daily targets are clearly identified, achieved and that all work is carried
out efficiently and effectively in accordance with scheduling, health, safety and quality requirements
[7].
Electrical/Electronics Supervisors Duties include:
 Responsible for the electronics and electrical services provided to clients on site and the day to
day supervision and monitoring of all ongoing work on site.
 Supervise and coordinate on-site teams and sub-contractors, ensuring they complete tasks on
time and safely to required standards
 Allocate work and ensure completion in accordance with the project schedule.
 Provide supervision and monitoring of costs, schedules, safety and direction on all project works
 Adhere to all Statutory Standards and Regulations
 Responsible for daily checks on all plant and equipment so that they work at optimum efficiency
 Create, allocate and control shift requirements for all teams/sub-contractors and maintain
relevant records
 Assist teams with resolving matters arising
 Cover other supervisors, as required
 Responsible for ensuring that teams and subcontractors deadlines are met with due care, without
undue delay
 Directly accountable for day to day requirements of project stakeholders
 Plan and organize ad-hoc works and/or variation requests together with planned activities for
plant and equipment
 Keep up to date with and have an awareness of, new Repaired Product Products and new
improved working methods that can add value by improving quality and reducing costs
 Complete project documentation and reports accurately and concisely
 Identify corrective actions and implementation of countermeasures to maximise Repaired Product
Productivity
 Responsible for all plant and equipment on hires, off hires, breakdowns, corrective actions and
counter-measures
 Ensure relevant materials and consumables are identified, sourced and delivered in a timely
manner to minimize project disruptions maintaining records and controlling stoc
 Maintain effective health and safety systems, including completion of risk assessments, method
statements, tool box talks, etc.
Safe work describes that an employer and/or person conducting a business or
When to Advice
undertaking must consult with workers when they are likely to be or are directly
affected by a situation involving their health and safety. In these situations, workers must have to
have an opportunity to express their views and contribute to any decisions relating to their health and
safety. this can be through work health and safety representatives, committees, or other regular
meeting forums. For instance, any change to equipment, even for risk control purposes, must be
discussed with workers before the change is made. Workers also need to be involved in any
conversation about the adequacy of facilities.
Employers must consult when:
 Identifying hazards and assessing risks
 Making decisions about ways to eliminate or control risks
 changing or updating workplace facilities
 Proposing changes that may affect the health and safety of workers
 Making decisions about consulting procedures, resolving safety issues, monitoring workers’ health
and conditions, and providing information and training.
Self-Check 4
Written Test
1. Employers must consult when?
A) Identifying hazards and assessing risks B) changing or updating workplace facilities
C) Making decisions about ways to eliminate or control risks D) All
2. ________describes that an employer and/or person conducting a business or undertaking must
consult with workers when they are likely to be or are directly affected by a situation involving their
health and safety.
A) Safe work B) Employee advice
B) both D) None
3. ___________is the one who takes care of the area of control and systems and leads the company
plants.
A) Electrical Engineering consultant B) Safe work
C) Employee Advice D) All
1. what are the key responsibilities of electrical/electronics supervisor?
2. what are duties of Electrical supervisor?
3. how to seek advice from electrical supervisor?
4. what are the relationship between electrical supervisor and workers?
Score___________
Rating___________
Information Sheet 5 Taking Required Material Sources
Occupational health and safety manual

The Electrical Safety Manual is divided into three Parts:
a. Part I: Electrical Hazards
b. Part II: Electrical Safe Work Practices
c. Part III: Acronyms, Definitions and Appendices
Industry/workplace codes of practice

WHS Regulation s34-38 In order to manage risk, a duty holder must:
 Identify reasonably foreseeable hazards that could give rise to the risk
 Eliminate the risk, so far as is reasonably practicable
 If it is not reasonably practicable to eliminate the risk, minimize the risk so far as is reasonably
practicable by implementing control measures
 Maintain the implemented control measure so that it remains effective
 Review, and if necessary revise, all risk control measures so as to maintain, so far as is
reasonably practicable, a work environment that is without risks to health and safety.
This Code includes guidance on how to manage electrical risks associated with working near
overhead and underground electric lines by following a systematic process that involves:
 Identifying hazards
 If necessary, assessing the risks associated with these hazards
 Implementing and maintaining risk control measures (e.g. inspecting and testing specified
electrical equipment, using safety switches)
 Reviewing risk control measures.
Reviewing the control measures The controls that are put in place to ensure electrical safety must be
reviewed regularly to make sure they work effectively.
WHS Regulation s38 A person conducting a business or undertaking must review and as necessary
revise a control measure in the following circumstances:
 When the control measure does not control the risk it was implemented to control so far as is
reasonably practicable
 Before a change at the workplace that is likely to give rise to a new or different risk to health or
safety that the measure may not effectively control
 If a new relevant hazard or risk is identified
 If the results of consultation indicate that a review is necessary
 If a health and safety representative requests a review.
ES Regulation s68 A person conducting a business or undertaking at a workplace must ensure, so
far as is reasonably practicable, that no person, plant or thing at the workplace comes within an
unsafe distance of an overhead or underground electric line. If it is not reasonably practicable to
ensure a safe distance; the person must ensure that a risk assessment is conducted for the proposed
work and control measures implemented are consistent with the risk assessment and, if an electricity
entity is responsible for the electric line, any requirements of the electricity entity.
What is an unsafe distance for an overhead electric line? ES Regulation s69 A person comes
within an unsafe distance of an overhead electric line if the person is within the exclusion zone for the
person for the line. Any operating plant, or a vehicle, comes within an unsafe distance of an overhead
electric line if the operating plant or vehicle is within the exclusion zone for the operating plant or
vehicle for the line.
Self-Check 5
Written Test
Part I Explain the following terms (each five points)
1. Explain Electric code of practice?
2. Explain ES Regulation s68 electric code?
3. What is an unsafe distance for an overhead electric line?
4. List Occupational health and safety manual

Score___________
Author/Copyright Servicing Management level IV Rating___________ February 2021
Operation
Operation Sheet #3 Prepare to find and repair faults
Title: - Taking Required Material Sources

PURPOSE: -
o The trainee’s will be able to prepare find and repair faults.
o The trainee’s will be able to Established source of material required for work
equipment.
Equipment, Tools & Materials: - T.W Batten 19mm x 13mm 42m 2), T.W batten 13mm x 13mm
10m 3), CTS/ T.R.S wire 13/. 039(3/22) 250v 4) Batten holder 2 no. 5) Plug 3pin, 5amp 1 no. 6)
Tumbler Switch one-way 5amp 3 no. 7) T.W round blocks (7.75cm x 2.5) 3 no. 8) T.W board 40
mm(1+1/2”) 9) Hink clip 40 mm(1/2”) 10) Wood Screw.
Procedure: - 1. Workplace guidelines/ workshop manuals

 Step 1: Draw the tangent or wiring on the board with cholk.
 Step 2. Cut the required length of T.W batten file and link chips on then and file
the batten with screw of 3mm size.
 Step 3. Cut the C.T.S wire in required length and put them on batten gripped by
link chips or per circuit diagram.
 Step 4. Fix the T.W round blocks and board after drilling the holes for wire.
 Step 5. Fix the batten holder, 3-pin plug and switch on round block.
 Step 6. After completing wiring it should be checked before supplying current.
Precautions:-
 Tools should be used carefully.
 Fitting should be tightly fitted.
 Connection should be tight.
 Wire should be on the conduit, power gripped properly
Quality Criteria:-
 The trainee’s make design of stair case wiring
LAP TEST #3
Name: ____________________________________ Date: ________________________

teacher.
1. Which type of switch we use in stair case wiring?

2. Where we use two-way switches?
3. Which tools are used for wiring?
4. What is the main precaution for staircase wiring?
 Antistatic mat
 Antistatic box
Information Sheet 6 Obtaining Tools, equipment and testing devices
6.1. Obtaining Tools, Equipment and Testing Device

When you’re just getting started, it is difficult to know what tools are or not essential, or what are the
best tools. This list contains a lot of different tools. You don’t need to buy them all at once. Otherwise,
you’ll end up buying stuff that you don’t need or stuff you’ll never use! Start by purchasing a few
essential tools related to the projects you want to do. Then, as your lab, and your expertise starts
growing, upgrade you lab with new tools. Making electronics projects is a lot of fun and it is nice to
have a specific space to be our lab, a space where we have all we need to make our projects. It
doesn’t have to be a full room or a big space. But it’s important to have “the” space! A space that is
ours and where we can have all things we need to get the most of making electronics projects.
Figure 6.1. Tools
A millimeter is a measurement tool absolutely necessary. It helps you troubleshooting

Millimeter
your circuits. Sometimes your circuits may not work because of faulty wires. Checking
the connections with the millimeter can save a lot of time. If you’re looking for one, we truly
recommend an auto-range millimeter. The auto-ranging is a great advantage, because it saves you of
the hassle of having to guess which range of value the electrical characteristic you’re measuring falls
under.
Figure 6.2. Millimeter

Having a soldering station in an electronics lab is absolutely necessary, even if
Soldering Station
you don’t usually build permanent circuits. Many electronics components don’t
come with header pins or breadboard-friendly pins attached. In these cases, you’ll need to do some
soldering work. If you don’t do a lot of soldering, a simple soldering station will do the job. However,
we really recommend getting a good soldering station with enough wattage and adjustable
temperature. A good soldering station will last your entire life. If you’re looking for a soldering station,
you may be interested in reading our suggestions about the best soldering irons for beginners and
electronics hobbyists.
Figure 6.3. Soldering Stations
If you are limited in terms of space, you may want to get a small portable soldering iron. We really
recommend the TS80 mini portable soldering iron. It is as good as a regular soldering iron and
occupies very little space.
Oscilloscope
An oscilloscope is a great tool for debugging and better understand what is going on with your
circuits. Unlike a millimeter that only shows the voltage at a specific moment, with an oscilloscope you
can see what’s happening with the voltage over time. We have an Hantek DSO5102P Digital Storage
Oscilloscope (DSO) and it is a great entry-level oscilloscope for students, beginners.
Figure 6.4. Hantek DSO5102P Digital Storage Oscilloscope 2Channels 100MHz 1GSa/s
A needle-nose pliers is always handy. You should absolutely

Needle-nose Pliers and Wire Cutter
get one. Wire cutters are also absolutely essential.
Precision Screwdriver Set

Figure 6.5. Needle-nose Pliers and Wire Cutter
There are components with really small screws
and with specific shapes and so, at some point in your projects, you’ll need a precision screwdriver.
We recommend you getting a set take comes with extension bits because you’ll need all of them
sooner or later.
Figure 6.6. Precision Screwdriver Set
Tweezers
Tweezers are very useful to manipulate the small electronics components. The tweezers below have
an extremely small and pointed tip, which is perfect for electronics.
Figure 6.7. Tweezers

Rotary Tool and Accessories
A rotary tool is great if you like to give your projects a good finished look. This tool is good for working
with acrylic, plastic, wood, and more. This tool is not essential for your lab, but it can be very useful.
Figure 6.8. Rotary Tool and Accessories

JUMPER WIRES
Jumper wires are really handy to connect components together. We recommend getting female to
female, male to female, and male to male jumper wires.
Figure 6.9. 120pcs Multicolored Dupont Wire Kit 40pin Male to Female, 40pin Male to Male, 40pin
Female to...
Figure 6.10. Remington Industries Solid Hook-Up Wire Kit, 300V, 0.0253" Diameter, 25' Length
VARIED SENSORS AND MODULES
There are a wide variety of sensors and modules compatible with Arduino and other development
boards. You can get some of them for a very reasonable price. Check the all the sensors options at
our tools page.
Figure 6.11. Elegoo Upgraded 37 in 1 Sensor Modules Kit with Tutorial for Arduino
An Arduino Starter Kit is the easiest way to start with digital electronics and
Arduino Starter Kit
programming. We have a full post dedicated to Arduino Starter Kits that you
can read here.
Figure 6.12. Elegoo EL-KIT-001 UNO R3 Project Complete Starter Kit with Tutorial for Arduino (63
Items).
Figure 6.13. ARDUINO The Starter Kit
A cabinet organizer is essential so that you have all your components
Cabinet organizer
organized. We’ve put together a list with the Best Storage Organizers For
Electrical/Electronic Components and Parts.
Figure 6.14. Akro-Mils 10164 64 Drawer Plastic Parts Storage Hardware and Craft Cabinet
Self-Check 6
Written Test
Part I Choose the best answer (each two points)
1._____________is tool is good for working with acrylic, plastic, wood.
A) Millimeter B) Screw Driver
C) Rotary Tool and Accessories D) All
2.____________ components with really small screws and with specific shapes and so, at some point
in your projects, you’ll need a precision screwdriver.
A) Precision screw driver B) Millimeter
C) Screw driver D) Oscilloscope
3. ____________is a great tool for debugging and better understand what is going on with your
circuits.
A) Oscilloscope B) Screw driver
C) Tools D) None
4. ___________is the easiest way to start with digital electronics and programming
C) Jumper wire
A) Arduino Starter Kit B) Multimeter
D) All
Part two II Explain the following terms (Each three points)
1. What is the use of jumper wire for mechatronics device?
2. What is the use of Multimeter for mechatronics device?
3) What is the use of Precision screw driver for Mechatronics device?
4) what is the use of Oscilloscope for mechatronics device?

Score___________
Rating___________
LG # 67 Lo #2- Find and Repair Faults
Instruction sheet
This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics:
 Following OH & S risk control measures and procedures.
 Determining the need to test or measure live.
 Checking the apparatus being isolated
 Approaching fault finding methodically.
 Dismantling Equipment components and parts.
 Rechecking faulty components and confirming their fault status
 Readjusting of Replacing Fault components
 Testing effectiveness of Repaired components
 Reassembling and testing Apparatus for return to customer
 Dealing with unexpected situations
 Carrying out fault finding repair activities efficiently without wastage and damage
This guide will also assist you to attain the learning outcomes stated in the cover
page. Specifically, upon completion of this learning guide, you will be able to:
 Follow OH & S risk control measures and procedures.
 Determine the need to test or measure live.
 Check the apparatus being isolated
 Approach fault finding methodically.
 Dismantle Equipment components and parts.
 Recheck faulty components and confirming their fault status
 Read just of Replacing Fault components
 Test effectiveness of Repaired components
 Reassemble and testing Apparatus for return to customer
 Deal with unexpected situations
 Carry out fault finding repair activities efficiently without wastage and
damage
Learning Instructions:
Read the specific objectives of this Learning Guide.
1. Follow the instructions described below.
2. Read the information written in the “Information Sheets”. Try to understand what are
being discussed. Ask your trainer for assistance if you have hard time understanding them.
3. Accomplish the “Self-checks” which are placed following all information sheets.
4. Ask from your trainer the key to correction (key answers) or you can request your trainer
to correct your work. (You are to get the key answer only after you finished answering the
Self-checks).
5. If you earned a satisfactory evaluation proceed to “Operation sheets
6. Perform “the Learning activity performance test” which is placed following “Operation
sheets” 7. If your performance is satisfactory proceed to the next learning guide,
8. If your performance is unsatisfactory, see your trainer for further instructions or go back to
“Operation sheets”.
Information sheet 1: Following OH & S risk control measures and procedures.
1.1 Following OH & S risk control measures and procedures.

A health and safety program is a definite plan of action designed to prevent accidents and
occupational diseases. Some form of a program is required under occupational health and safety
legislation in most Canadian jurisdictions. A health and safety program must include the elements
required by the health and safety legislation as a minimum, because organizations differ, a program
developed for one organization cannot necessarily be expected to meet the needs of another. This
document summarizes the general elements of a health and safety program. This approach should
help smaller organizations to develop programs to deal with their specific needs
Canadian health and safety legislation requires employers to have a health and safety program in
their workplace. A written occupational health and safety policy helps promote an effective OHS
program. Such a policy should reflect the special needs of your workplace and should be regularly
reviewed and updated. This document will assist you in writing and applying a policy for your
workplace. This policy communicates a commitment to health and safety. It should be signed by a
senior manager or president to further demonstrate the commitment to health and safety.
1.1.1 Safety precautions to take when working with electronic equipment
Safety is defined as the protection from harm, danger, risk, accident or injury. It is very necessary
usually occur due to lack of safety. Therefore safety is the most important in any industrial or
occupational setup. Almost all the accidents in usual lives to follow the safety rules and regulation at
all the works Therefore safety is the most important in any industrial
or occupational setup. When working with or testing any electronic equipment, it’s always important
to be cautious. Whatever type of equipment you’re handling, whether simple or complex, it’s
important to take the right safety precautions.
Working with electricity comes with huge risks that should never be taken lightly. If you’re a hobbyist
who loves working with electronic components or electronics professional at your workplace, safety
should always come first.
To avoid personal injury, possible damage to equipment or danger of fire, all work on electronic
equipment should be conducted following these safety procedures.
General Safety procedure
Before working on any electronics, consider following these basic safety precautions to help reduce
any hazards.
 Remove any electronic equipment you’re testing or working on from the power source.
 Never assume the power circuit is off. Test and test again with a voltmeter to confirm.
 Remove fuses and replace them only after the power to the circuit is disconnected.
 Don’t connect power to a circuit until you’re done working on it and rechecked the work.
 Always ensure that all electronics equipment is properly grounded
 If it’s damaged, replace it. For instance, replace cables instead of repairing with insulating tape.
 Always use the right electronics repair and maintenance tools.
 Always return covers after removing them to reduce the risk of electric shock.
 Make sure your circuit is not overloaded.
 Always have safety equipment like a fire extinguisher, a basic first aid kit and a mobile phone
nearby.
Personal Safety
It’s important to ensure that you’re safe when working on electronic circuits. Here are some personal
safety precautions to keep in mind
 Always keep your work area dry.
 Always work in a well-ventilated area.
 Don’t wear flapping or loose clothing when working.
 Don’t work with metallic jewelry on your hands like watches, rings and bracelets.
 Don’t use bare hands to remove hot parts.
 Always wear non-conductive shoes.
 Always wear insulator gloves in your hands when carrying out repairs.
 When removing high-voltage charges on capacitors, always use a shorting stick.
 Don’t hold the test prods when measuring voltage over 300V.
 Always remove power to a circuit before connecting alligator clips.
 Always wear safety goggles.
 Be careful when handling large capacitors as they can still hold high voltage even after you’ve
disconnected the circuit from power.
Self check:1 written test
I. Choose the best answer from the given alternatives. (5 pts each)
1. _______is a definite plan of action designed to prevent accidents and occupational

diseases.
a. Safety program c. health and safety program
b. High voltage d. a and c
2. From the following which one is used for Personal Safety
a. Always keep your work area dry.
b. Always work in a well-ventilated area.
c. Don’t wear flapping or loose clothing when working.
d. all
Note: Satisfactory rating above 25 points Unsatisfactory - below 25

Score___________
Rating___________
Information sheet 2: Determining the need to test or measure live.
2.1 Determining the need to test or measure live.

What is testing?
Testing is the practice of making objective judgments regarding the extent to which the system
(device) meets, exceeds or fails to meet stated objectives
Purpose of testing
There are two fundamental purposes of testing: verifying procurement specifications and managing
risk. First, testing is about verifying that what was specified is what was delivered: it verifies that the
product (system) meets the functional, performance, design, and implementation requirements
identified in the procurement specifications. Second, testing is about managing risk for both the
acquiring agency and the system’s vendor/developer/integrator. The testing program is used to
identify when the work has been “completed” so that the contract can be closed, the vendor paid, and
the system shifted by the agency into the warranty and maintenance phase of the project.
Methods used to conduct testing
There are five basic verification methods, as outlined below.
 Inspection - Inspection is the verification by physical and visual examinations of the item reviewing
descriptive documentation, and comparing the appropriate characteristics with all the referenced
standards to determine compliance with the requirements.
 Certificate of Compliance - A Certificate of Compliance is a means of verifying compliance for
items that are standard products. Signed certificates from vendors state that the purchased items
meet procurement specifications, standards, and other requirements as defined in the purchase
order. Records of tests performed to verify specifications are retained by the vendor as evidence that
the requirements were met and are made available by the vendor for purchaser review.
 Analysis: is the verification by evaluation or simulation using mathematical representations, charts,
graphs, circuit diagrams, calculation, or data reduction. This includes analysis of algorithms
independent of computer implementation, analytical conclusions drawn from test data, and extension
of test-produced data to untested conditions.
 Demonstration - Demonstration is the functional verification that a specification requirement is met
by observing the qualitative results of an operation or exercise performed under specific condition.
This includes content and accuracy of displays, comparison of system outputs with independently
derived test cases, and system recovery from induced failure conditions.
 Test (Formal) - Formal testing is the verification that a specification requirement has been met by
measuring, recording, or evaluating qualitative and quantitative data obtained during controlled
exercises under all appropriate conditions using real and/or simulated stimulus. This includes
verification of system performance, system functionality, and correct data distribution.

1. ______is the practice of making objective judgments regarding the extent to which the system
(device) meets, exceeds or fails to meet stated objectives
a. Testing c. design
b. performance d. implementation
2. Choose the purposes of testing from the following:
a. Verifying procurement specifications c. a and b
b. Managing risk d. all
3. ______ is the verification by evaluation or simulation using mathematical representations
Analysis, charts, graphs, circuit diagrams, calculation, or data reduction. T
a. Demonstration c. Inspection
b. Analysis: d. certificate of compliance
4. _________is the verification by physical and visual examinations of the item reviewing
descriptive documentation, and comparing the appropriate characteristics with all the
referenced standards to determine compliance with the requirements.
a. Demonstration c. Inspection
b. Analysis: d. certificate of compliance

Score___________
Page 52 of 120 Federal TVET Agency TVET program title : Mechatronics andRating___________
Instrument Version -1
Information sheet 3: Checking the apparatus being isolated
3.1 Checking the apparatus being isolated.

 Multi-meter
Once you have determined the most probably cause of a fault, you must either prove it to be the
problem or not. This can sometimes be done by careful inspection but in many cases the fault will
be such that you cannot identify the problem component by observation and analysis alone. Here,
test instruments can be used to help narrow the problem area and identify the problem
component.
Figure 3.1: Multimeter

General Meter Rules
There are many types of test instruments used for troubleshooting. Some are specialized instruments
designed to measure various behaviors of specific Equipment. There are other types of test
instruments such as multimeters which are more general in nature and can be used for most
electrical measurement. A typical multimeter can measure AC and DC Voltages, Resistance and
Current. Before you use a meter to make a test you should know what the meter will read if the
circuit is operating normally. You should make your prediction of the reading expected, based on the
circuit schematic. If the reading is anything other than your predicted value, you know that this part of
the circuit is being affected by the fault.
You should always check the meter before using it to troubleshoot.
 For a voltmeter, test the meter on a known voltage source before using. Your meter should read
the correct voltage.
 For an ohmmeter, touch the meter leads together. The display should read 0 ohms or very near
this. With the leads apart it should read OL (infinity).
Meter Precautions
Here are some more Do’s and Don’ts for using a meter.
 Be familiar with its features. Read the instruction manual before using.
 Ensure it is safe to use – no obvious damage to the meter or the meter leads.
 Be sure the test leads are in the correct sockets and the rotary switch is in the correct position
for the desired measurement.
 Never measure resistance in a circuit when power is applied.
 Never apply more than the rated voltage between any input jack and ground.
 Keep your fingers behind the finger guards on the test probes when making measurements.
 To avoid false readings, which could lead to possible electric shock or personal injury, replace
the battery as soon as the battery indicator appears.
 Testing Live vs. Dead

One of the first things you must decide is whether the circuit can be alive or must be dead while
testing. Performing certain tests while a circuit is alive can be very helpful. However, some
companies have policies that ban (or restrict) testing live circuits while troubleshooting. Before doing
any testing makes sure you check your company’s policy. This module does contain certain
techniques used to test a de-energized circuit.
Faults can generally be categorized into either open circuits or short circuits. Open circuits occur
when there is a break in the circuitry. This could be a broken wire, loose connection, burned out
component, etc. Short circuits occur when two or more components, which should be isolated, come
in contact with each other. For example, the insulation on wiring could decay and the conductors
short together or short to ground
Figure 3.2: open and short circuit identification
Sectionalizing Circuits with Meters
Sometimes you will be faced with a problem that there are few useful observations and the problem
area is a large portion of the circuit. It may not be feasible to begin testing all the components in the
problem area. You should still start with the component you identified as the most probable cause. If
this component is not the actual cause, the meter readings will provide you with information that
reduces the size of the problem area and points you in the direction of the fault. This is called
sectionalizing. The meter techniques described in this section use this concept in determining where
to test.
 Using a Voltmeter
Voltmeters are the best tool to use for finding open circuits – if you can safely turn the power on.
Once you know it is an open circuit and have determined the general area of the fault, get your
voltmeter out and check that it is working on a known source.
Connect the negative lead to a known reference. The negative (neutral or ground if on AC) supply is
preferable. Test through the affected circuit with your other lead, making sure all necessary switches
are closed. The wire or device between the last point you test full voltage and the first place you don’t
get full voltage is where the open circuit is located.
Figure 3.3 ohmmeter use

 Ammeter
With an ammeter, you can measure the current flowing through a circuit. This can be very useful
when your other test instruments (voltmeter and ohmmeter) are not appropriate.
For example, measuring the current in each phase of a 3 phase motor can provide very important
clues as the motor behavior.
There are two ways to use an ammeter.
The first way is to connect the meter leads into the appropriate sockets on the meter and then insert
the meter into the circuit. To do this you must first lockout the circuit, disconnect a terminal where you
want to test and then connect the leads between the terminal and the wire as shown. When using this
method you must be sure that the current you are about to measure will not exceed the maximum
value for the meter.
Figure 3.6: how to use ammeter
Another option for measuring current (AC current only) is to use a clamp-on probe instead of the
meter leads. One end connects into the appropriate sockets on the meter and the other end consists
of a spring operated circular clamp, which can be clamped around a wire. The clamp is really a small
transformer that can sense the current flowing through the wire and send this information to the meter
to be displayed.
This type of reading has the advantage that you do not need to disconnect any wires in the circuit.
This type of ammeter is used in Smutch’s troubleshooting simulators.
 Oscilloscope
An oscilloscope is easily the most useful instrument available for testing circuits because it allows you
to see the signals at different points in the circuit. The best way of investigating an electronic system
is to monitor signals at the input and output of each system block, checking that each block is
operating as expected and is correctly linked to the next. With a little practice, you will be able to find
and correct faults quickly and accurately.
An oscilloscope is an impressive piece of kit:
Figure 3.5: Oscilloscope

How to use an oscilloscope
Each station includes an oscilloscope with two probes. The oscilloscope is an instrument that
basically displays the graph of an electrical signal, usually voltage as a function of time. It is generally
useful in cases where there is a rapidly changing voltage as a function of time.
Using the Oscilloscope, you can determine:
• The magnitude of the voltage and how it is varying with time,
• The frequency of an oscillating signal,
• How much of your signal contains a DC component and an AC component,
• How much noise there is in your signal and how that noise is varying with time, and
• If there is a malfunctioning component in a circuit by observing the response of the circuit
1. ______is easily the most useful instrument available for testing circuits because it allows you
to see the signals at different points in the circuit.
a. Oscilloscope c. Voltmeter
b. Ammeter d. Multimeter
2. Using the Oscilloscope, you can determine:
a. The magnitude of the voltage and how it is varying with time,
b. The frequency of an oscillating signal,
c. How much of your signal contains a DC component and an AC component,
d. How much noise there is in your signal and how that noise is varying with time, and
e. If there is a malfunctioning component in a circuit by observing the response of the circuit
f. all
3. Voltmeters are the best tool to use for finding open circuits – if you can safely turn the power
on.
a. Oscilloscope c. Voltmeter
c. Ammeter d. Multimeter
d.
e. Score___________
Rating___________
Information sheet 4: Approaching fault finding methodically
4.1 Approaching fault finding methodically
General fault-finding for electricity/electronics equipment is skill that is neither and art nor a science,
but an angering discipline in its own right.
Effective faulty finding requires:
 A good general knowledge of electricity and electronics
 Specialized knowledge of the faulty equipment
 Suitable test equipment
 Experience in using such test equipment
 The ability to formulate a procedure for isolating a fault.
 The availability of service sheets and other guides
A good general knowledge of electricity/electronics is essential because not all equipment is well
documented, and in some cases only a circuit diagram (or even nothing at all) may be available as a
guide. Failing a concise description of how the equipment works, you may have to work out for
yourself the progress of a signal through the equipment. In addition, a wide general knowledge is
needed if you are to make reasonable assumptions about how to substitute components. You are not
likely to know why something does not work if you do not know what does make it work.
Repair is mainly “setting the device back to the condition of normal operation, because we presume
the device brought to us for repair has worked before properly”. We can presume as well most of the
preconditions - necessary for correct operation - are still given. Only a few - if not a single -
components are defect. Such a defect cause
 a lag of voltage at a number of terminals
 lag of current through some wires-
 Change of resistance of the component.
Measurement of voltage, current or resistance can therefore serve as a reference to locate the
actual fault. When you are searching for those effects of faults the various measured values are
compared with the values expected (or given in the data sheet).
We call the methods:
 Voltage analyzing
 Current analyzing and
 Resistance analyzing
The voltage analyzing is the most often used one; because it can be carried out without any
mechanical change of the device (voltage can be measured in parallel
Voltage analyzing
Here we mostly start to measure the voltages at the power-supply and then the voltages at the
supplying terminals of the blocks. If we find a voltage missing or a strange value we have to consider
what could be the reason for this effect.
Current Analyzing
Real current measuring is undertaken only in very special cases, because it is necessary to open the
circuit, and this means actually to dissolder a terminal of a component. This is time consuming and
endangering the circuit, because you could break a connection.
Therefore direct current analyzing is used only in a few special cases:
If it is urgently necessary (because voltage measurement does not help anymore) or if it is extremely
simple to undertake it (for example at a fuse, a contact of a switch or special plugged in links).
But you can very often measure the current indirectly by measuring the voltage across a resistor
which is passed by this current. if you know what is the resistance of this resistor you can determine
the current by ohm's law.
Resistance Analyzing
Resistance analyzing has to be done while the device is switched off only (otherwise you can easily
spoil the measuring instrument).
Importance of fault finding
Faulty finding is an activity during which somebody who is undertaking it has to keep in mind
economical questions in order to be able to earn his living.
During the overall activity of repairing equipment the section fault finding has an overwhelming
importance. If a fault has been located it has lost its “horror”, because its remedy requires only some
rather simple skills and some knowledge about components and materials.
If repair is done as a business, fault finding is a main factor of calculation of costs. The time
consumed for it is a very big portion of the overall time spend for the repair. A quick location of faults
is therefore reducing the costs and gives so the professionalism a big advantage in competition.
If repair is done as a business, fault finding is a main factor of calculation of costs. The time
consumed for it is a very big portion of the overall time spend for the repair. A quick location of faults
is therefore reducing the costs and gives so the professionalism a big advantage in competition.
To be able to choose the fitting method of fault finding under special circumstances, it is necessary to
have a general view of all possible methods to track down faults. An important role plays the
measuring instruments.
Instruments, finding devices, signal generators and so on, are items which are very expensive and
therefore must enter the calculation of costs as well.
Even if a beginner does not have all instruments available on the market he has a big advantage if he
has a profound knowledge of all possible methods because he is only then able to apply the best
method which will cause the smallest costs.
Fault finding procedures
Having established the symptoms of a fault it is then necessary to conduct tests to confirm the
symptoms and to attempt to determine the location of the fault within the equipment. A sound
knowledge of the technical concepts and the operation of the system may assist in locating the fault
but sometimes the testing will be extensive and an overall procedure should be adopted.
Figure 4:1 Fault finding procedures
page:
1. Effective faulty finding requires:
a. A good general knowledge of electricity and electronics
b. Specialized knowledge of the faulty equipment
c. Suitable test equipment
d. Experience in using such test equipment
e. All
2. Components are defect. Such a defect cause

a. a lag of voltage at a number of terminals
b. lag of current through some wires-
c. Change of resistance of the component
d. all
3. ________is an activity during which somebody who is undertaking it has to keep in mind
economical questions in order to be able to earn his living.
a. Troubleshooting
b. Diagnosing
c. Faulty finding
d. all
4. _________ is the most often used one; because it can be carried out without any mechanical
change of the device (also it can be measured in parallel.
a. Voltage analyzing c. Voltage analyzing
b. Current analyzing d. none
5. __________is undertaken only in very special cases, because it is necessary to open the
circuit, and this means actually to dissolder a terminal of a component.
c. Voltage analyzing c. Voltage analyzing
d. Current analyzing d. none

Score___________
Rating___________
Operation Sheet #1 Find and Repair Faults
Operation Title: - Approaching fault finding methodically

PURPOSE: -
o The trainee’s will be able to create back up for documents.
o The trainee’s will be able to perform faulty finding methodology
equipment.
Equipment, Tools & Materials: - electrical workshop, electronics tool kit, multimeter, screw driver,
test light, brush, circuit boards, portable power tool like drilling machine.
Procedure: - 1. Fault finding procedure
 Step 1: Get the previous symptom if any from the user
 Step 2: Inspect visually for physical damage
 Step 3: Look equipment for burning smell
 Step 4: Look the manual for test point provided by manufacturer
 Step 5: As per instruction of manual find out the sub-section in
Which fault occur
 Step 6: Check proper dc voltage/current in that sub-section/circuit/.
 Step 7: If found improper voltage/current replace faulty
Parts/section /in the circuit /
 Step 8: Test for performance for satisfactory result
 Step 9: If fault persist repeat the process
Precautions:-
 Document everything (backup).
LAP TEST #1
Name: ____________________________________ Date: ________________________

teacher.
1. How to finding faulty an electronics equipment?
 Electrostatic wrist strip
 Antistatic mat
 Antistatic box
Dismantling Equipment components and parts
Information sheet 5
5.1 Dismantling Equipment components and parts

This procedure describes the process for dismantling branded electronic/electrical products
manufactured and/or sold within the EU in compliance with electrical/ electronic equipment
requirements. The dismantling instructions are intended for use as guidelines by dismantlers or
recyclers when processing end-of-life products. Ensures equipment is properly labeled and
disposed of in line with the WEEE requirements. Dismantlers / Recyclers: Strips products damaged
or beyond useful life into material types providing savings on landfill weight and costs
Equipment
The list below represents general and specialty tools used in the dismantling of Smith & Nephew
Endoscopy products.
 Phillips and flat screwdrivers #1 and #2
 Pliers and wire cutters
 Oval head cutter
 3/16-inch nut driver
 1/4-inch Hex nut driver
 Allen wrenches
 TR 10 x 50 tamper-resistant Torx driver (WIHA 7045)
 Wrench, 10 mm open end
Procedure
Note: Please follow the general safety and personal protection precautions in your facility
when dismantling.
Dismantling consists of several subassembly groups for numerous Smith & Nephew Endoscopy
products. Please follow the instructions listed below. Individual waste containers should be labeled
and used accordingly.
The table below lists material types that can be found in Smith & Nephews Endoscopy products.
Metals Plastics Electronics Other

Aluminum Noryl PC boards Heat shrink tubing
Stainless steel Acetyl Cable assemblies Foil tape
Plain steel w/ plating Tie wraps Computer drives Rubber feet
Copper ABS Fans and connectors BG39 glass
Brass PVC Switches & membranes BK7 glass
Carbon steel Polyethylene AC receptacle Charcoal foam
Titanium Polypropylene Electric valves Lamps
Nylon AC power switch Glass
Silicone rubber Stranded wire
Polyetheretherketone Coaxial wire
Polyphenylsulfone RF filter
Ethylene propylene Speaker
Delran Power supply
Cycolac
 Removal of Cover
Remove the main cover by taking out the screws in the back of the unit. Place the hardware and
cover in the metals waste container.
 Removal of Cable Assemblies and Wiring
cut all the tie wraps that are securing the cable assemblies. Place them in the plastics waste
container. Remove cable assemblies and wires by disconnecting them or cutting the leads flush
with the connectors. Place the cables in the electronics waste container. Place the connectors in
the plastics waste container.
Exception: There are some cable assemblies that have metal connectors (VGA, USB, etc.). Place
these connectors in the metals waste container after removing them from the cable assembly.
Note: Access to some cable assemblies can only be achieved by removing components above or
around them during the dismantling process.
Where feasible, cable assemblies with ferrite beads attached should have the ferrite removed from
the cable assembly and placed in the metals waste container. Some cable assemblies are an integral
part of an electronic component and cannot be removed by dismantling. Discard the component with
cable assembly attached in the appropriate waste container.
 Dismantling of rear panel
Remove all electrical type components such as the fan, switch, and AC receptacle and place them
in the electronics waste container. Other components such as the metal fan shields and connectors
can be placed in the metals waste container. Place all plastic components such as plastic fan
shields in the plastic waste container. The handle (if applicable) and equipped may be left
assembled to the chassis or removed and placed in the metals waste container. The rear overlay is
attached by a PSA adhesive and can only be removed with solvent. It is recommended
that the rear overlay remain attached to the chassis.
Dismantling of front panel
Dismantle the bezel assembly by removing the fasteners from the chassis. Place the fasteners in
the metals waste container. If any cable assemblies or PC boards or switches are mounted to the
bezel, remove and place them in the electronics waste container. If the unit consist of any knobs
dispose of them in the appropriate waste container. Front panels containing a front overlay are most
likely attached by a PSA adhesive and can only be removed with solvent. It is recommended that
the front overlay remain attached to the bezel. The bezel is an injection molded plastic and should
be placed in the plastics waste container.
Removals of pc boards
The PC boards (PCB's) are typically secured by fasteners and, in some cases, are in a stacked
assembly in the unit. Remove the fasteners and place them in the metals waste container or plastics
waste container according to the fastener material, remove the PCB's and place them in the
electronics waste container. PCB's can consist of sheet metal brackets used for mounting or there
may be metal stand offs used. As they are encountered and disassembled place them in the metals
waste container. Continue the dismantling process from the top down until all PCB's, fasteners, and
shielding are removed and discarded as indicated.
Dismantling of other components (not previously mentioned)
After the dismantling of the front and rear panels along with the removal of all cable assemblies and
PC boards, there can be several miscellaneous components remaining that have not been
specifically mentioned for removal. These components can consist of the following items at a
minimum:
 Power Supplies
 Keyboards
 Displays
 Hard Drives
 Motors
 Lamp Assemblies
 Speakers
Remove all remaining items and place them in the appropriate waste container. Place the fasteners in
the metals waste container.
Dismantling of Chassis
At this point in the process there should only be the chassis with very few components remaining.
Check the bottom of the chassis for possible mounting feet. Chassis feet are typically plastic or
rubber and attached by fasteners or adhesive. Remove the fasteners if applicable and place them in
the metals waste container and place the feet in the plastics or other materials waste container
accordingly. Remove any remaining non-metal items such as plastic wire ducts and dispose in the
appropriate waste container. The chassis should now be free of all components. Place it in the metals
waste container.
page:
I. Write the answers of the following questions
1. Define dismantle (15)?
Score___________
Rating___________
Information sheet 6: Rechecking faulty components and confirming their fault
status
6.1 Rechecking faulty components and confirming their fault status
Measurement of voltage, current or resistance can therefore serve as a reference to locate the
actual fault. When you are searching for those effects of faults the various measured values are
compared with the values expected (or given in the data sheet
Fault Condition reporting while repairs are under way it is sometimes necessary to hand over the
work or the equipment to someone else. If this is to work efficiently you must be able to pass on all
relevant information. This is also important to ensure the safety of all personnel while the system is
not in its usual operating condition.
 The steps involved are:
A. Document all changes to normal operational line-up either in the log or, if the system is in use, on
forms supplied for this purpose. You should also make notes in your personal journal.
B. Set out work schedules in accordance with safe practices and nominated company procedures.
This may require you to document all notifications given to relevant persons together with
Authority to Carry Out Running Repairs, Work Permits, Clearance Certificates, Tags(Danger and
Out of Service, etc.) Locks and Sentinels in operation or other applicable special precautions.
C. Highlight any special precautions or fallback procedures relating to operation of running
equipment.
D. Prepare a concise report on the current status of the repair being undertaken including personnel
involved, equipment or tooling obtained, equipment or tooling ordered or required, parts
availability, strip-down status of the machine and estimated completion time.
E. Pass on findings in regard to component condition or potential weaknesses found during
dismantling and other information necessary for the person taking over to make informed
decisions.
F. Where practical, carry out a tour of inspection with the new person of the affected plant, pointing
out areas of concern and activities under way.
G. Ensure they have understood you and have a clear picture of the situation and its implication
Localizing the faulty function
 Isolating the functional area that has an indication of malfunction.
 Knowledge, skill, and proper test equipment should now be used to isolate the faulty functional
area
page:
1. How to rechecking component faulty? (15)
Score___________
Rating___________
Rechecking faulty components and confirming
Operation Sheet #2
their fault status
Operation Title: - Rechecking faulty components and confirming their fault status
PURPOSE: -
o The trainee’s will be able to create back up for documents.
o The trainee’s will be able to perform Rechecking faulty components Conditions or
situations for operation: - Have a clean workspace with all necessary tools and
equipment.
Equipment, Tools & Materials: - electrical workshop, electronics tool kit, multimeter, screw driver,
test light, brush, circuit boards, portable power tool like drilling machine.
Procedure: - 1. Rechecking faulty components (Failure analysis)
Steps 1 and 2 were used to recognize, verify, and obtain descriptive information
Step 3 allowed you to make a logical selection of the logical faulty unit
Step 4 provided for simple input-output tests and localized the faulty functions
Step 5 localized the fault to the circuit within the faulty unit
Step 6 will involve the actual replacement or repair of faulty circuit components
Precautions:-
 Document everything (backup).
Quality Criteria:-
 The trainee’s make rechecking faulty components Conditions
LAP TEST #2
Name: ____________________________________ Date: ________________________

teacher.
1. Rechecking faulty components (Failure analysis)?
 Antistatic mat
 Antistatic box
Information sheet 7: Readjusting of Replacing Fault components
7.1 Readjusting of Replacing Fault components

This information sheet describes common tasks that must be completed prior to performing a
readjusting of replacing procedure on faulty component
The procedures described in this information sheet are written for workstation service faulty
component.
Safety Information
This section provides safety precautions to follow when readjusting of replacing faulty component
Workstation.
Safety Precautions
For your protection, observe the following safety precautions when setting up your equipment:
 Follow all Sun standard cautions, warnings, and instructions marked on the equipment and
described in Important Safety Information for the component
 Follow the cautions, warnings, and instructions in the equipment, Safety and Compliance
Guide, The document is available at:
 Ensure that the voltage and frequency of your power source match the voltage and frequency
inscribed on the equipment’s electrical rating label.
 Never push objects of any kind through openings in the equipment. Dangerous voltages might
be present. Conductive foreign objects could produce a short circuit that could cause fire,
electric shock, or damage to your equipment.
Safety Symbols
 The following symbols might appear in this information sheet. Please note their meanings:
Caution - There is a risk of personal injury and equipment damage. To avoid
personal injury and equipment damage, follow the instructions.
Caution - Hot surface. Avoid contact. Surfaces are hot and might cause personal injury if
touched.
Caution - Hazardous voltages are present. To reduce the risk of electric shock and danger to
personal health, follow the instructions.
Electrostatic Discharge Safety
 Certain devices, such as the motherboard, PCI cards, and hard drives, are sensitive to
electrostatic discharge (ESD). They require special handling.
Caution - The boards and hard drives contain electronic components that are extremely
sensitive to static electricity. Ordinary amounts of static electricity from clothing or the work
environment can destroy components. Do not touch
the components along their connector edges.
Wear an antistatic wrist strap and use an antistatic mat when handling components such as
drive assemblies, boards, or DIMMs. When servicing or removing workstation components,
attach an antistatic strap to your wrist and then to a metal area on the chassis. Then disconnect
the power cord from the workstation and the wall receptacle. Following this caution equalizes
all electrical potentials with the workstation.
Required Tools
Though not required for component replacement, the following tools have proven helpful in certain
situations:
 Needle nose pliers, tweezers, or hemostat
 Large jeweler’s screwdriver
 Flashlight
Place ESD-sensitive components such as the motherboard, memory, PCI cards, and hard drives on
an antistatic mat. The following items can be used as an antistatic mat:
 Antistatic bag used to wrap a Sun replacement part
 Disposable ESD mat (might be shipped with replacement parts or optional system
components)
Preparing the Workstation for Servicing
To prepare the workstation for servicing
Power off the workstation
Save your data and close any open applications.
Read all of the following power-off options before powering off the workstation:
Power off the workstation by using the operating system shutdown command or the menus in most
cases, this shuts down the operating system, then turns off the power to the workstation. If the
operating system shutdown procedure fails to power off the workstation, or if it is not available, press
and release the Power button shown in. This initiates an orderly shutdown of the operating system
and powers off the workstation.

page:
1. Write safety precautions when setting up your equipment(20):
Score___________
Rating___________
Information sheet 8 : Testing effectiveness of Repaired components
8.1 Testing effectiveness of Repaired components

The primary method for fixing a defect or fault is repair. If repairing is impossible or would cause
unreasonable costs, the item can be replaced with a faultless one.
The liable company has the right to repair the defect or fault if it offers to do so immediately after
receiving notice of the problem from the buyer and the repairs are done within a reasonable time,
without causing a decrease in the value of the item and without undue inconvenience for the buyer.
The consumer has the right to refuse the offer of repairing the item if it would cause significant
inconvenience or a decrease in the value of the item, or if there is the risk that the costs incurred
by the consumer will not be compensated.
A defective item can be replaced with a faultless one if repairing is impossible or would cause
unreasonable costs. If the warranty is still valid, the warranty period is not extended due to the
replacement: the original warranty will remain in place. The replacement item must correspond to the
defective one in value and quality, and it must fulfill the criteria according to which the consumer
purchased the original one.
The company may refuse to supply a faultless replacement item if this would cause unreasonable
costs – for instance when the item was made to measure or if it is no longer manufactured.
If it is impossible to either repair or replace the goods, the company may provide compensation in the
form of a discount or a complete cancellation of the sale. Consumers are not obliged to accept a gift
voucher or other product in lieu of reimbursement of the purchase price.
Consumers are also entitled to compensation for any damages caused by the defect in the goods.
If the full purchase price has not yet been paid, the consumer has the right to withhold a portion of the
sum that corresponds to the defect until the defect has been repaired or otherwise compensated for.
The rest of the purchase price must be paid in accordance with the sales contract.
The vendor is liable for defects in the goods in accordance with the stated terms of the warranty. The
vendor is also responsible for the warranty granted by the manufacturer or importer, unless the
vendor has specifically stated otherwise prior to the sale.
The party granting the warranty is liable at its own expense to provide compensation for defects
arising during the warranty period. The liability is voided, however, if the warrantor can prove that the
defect was caused by the buyer, as, for example, in the case of:
 improper use of the goods
 failure to carry out proper maintenance in accordance with maintenance instructions
 external damage or accident
During the warranty period, the consumer cannot be required to pay for diagnostics (i.e. finding the
fault or defect). This does not apply if the buyer has clearly brought the goods in for repair
groundlessly or has caused the fault or defect.
If there is no warranty or the warranty has expired
No time limits are set by law for the vendor’s liability for defects. Instead, the period depends on the
expected useful life of the product or defective part. In other words, the company’s liability does not
end with the expiry of the warranty period.
When no warranty has been given or it has expired, the buyer is usually expected to prove the defect
or fault in the product. It is not necessary for the consumer to provide a highly detailed report of the
causes of the defect or fault, however, especially in the case of complex technical equipment.
This obligation of proof is mitigated by the fact that a product is considered to be defective if a fault or
defect arises significantly before the end of the normal useful life of the product or part, and the
vendor is unable to provide information to support the claim that the defect was caused by the buyer
or by another factor independent of the buyer.
The vendor is not liable for compensation if the fault is due to ordinary wear and tear, accident or
misuse.
Usually it is possible to charge the customer a reasonable sum for diagnostics, as long as this has
been mentioned or agreed in advance. The consumer has the right to receive a written report on the
diagnosed faults and how much they will cost to repair.

page:
1.write primary method for fixing a defect or fault component (20):
Score___________
Rating___________
Reassembling and Testing Apparatus for return to Customer
Information sheet 9
1.9 Profession mechatronics assembler

Mechatronics assemblers assemble and maintain complex mechatronic equipment and machines,
such as robots, elevators, and advanced home appliances. They build the mechanical, electrical, and
electronic components, install software, set the systems in operation, and maintain and repair the
components and systems.
Would you like to know what kind of career and professions suit you best? Take our free Holland
code career test and find out.
Personality Type
 Realistic / Conventional
Knowledge
 Computer equipment
The offered computers, computer peripheral equipment and software products, their
functionalities, properties and legal and regulatory requirements.
 Electronics
The functioning of electronic circuit boards, processors, chips, and computer hardware and
software, including programming and applications. Apply this knowledge to ensure electronic
equipment runs smoothly.
 Mechatronics
Multidisciplinary field of engineering that combines principles of electrical engineering,
telecommunications engineering, control engineering, computer engineering, and mechanical
engineering in the design of products and manufacturing processes. The combination of these
areas of engineering allows for the design and development of "smart" devices and the
achievement of an optimal balance between mechanical structure and control.
 Safety engineering
The engineering discipline used to ensure that systems, machines and equipment work according
to the set safety standards and laws, such as environmental law.
Reassembling and Testing Apparatus for return
 Follow safety standards in industrial contexts
Abide by safety procedures and standards for industrial contexts, mostly where machinery is
involved.
 Apply soldering techniques
Apply and work with a variety of techniques in the process of soldering, such as soft soldering,
silver soldering, induction soldering, resistance soldering, pipe soldering, mechanical and
aluminium soldering.
 Monitor machine operations
Observing machine operations and evaluating product quality thereby ensuring conformity to
standards.
 Apply assembly techniques
Apply correct and up-to-date assembly methods in the production development process.
 Align components
Align and lay out components in order to put them together correctly according to blueprints and
technical plans.
 Install mechatronic equipment
Install equipment used for the automation of a certain device or machine.
 Ensure conformity to specifications
Ensure that the assembled products are conform to the specifications given.
 Remove defective products
Remove defective materials from the production line.
 Meet deadlines
Ensure operative processes are finished at a previously agreed-upon time.
 Clean components during assembly
Clean components before fixing them to other compounds or units of components during the
assembly process.
 Read assembly drawings
Read and interpret drawings listing all the parts and subassemblies of a certain product. The
drawing identifies the different components and materials and provides instructions on how to
assemble a product.
 Maintain mechatronic equipment
Diagnose and detect malfunctions in mechatronics components and systems and remove,
replace, or repair these components when necessary. Execute preventative equipment
maintenance tasks, such as storing mechatronics components in clean, dust-free, and non-humid
spaces.
 Assemble mechatronic units
Assemble mechatronic units using mechanical, pneumatic, hydraulic, electrical, electronic, and
information technology systems and components. Manipulate and attach metals through using
welding and soldering techniques, glue, screws, and rivets. Install wiring. Install drive systems,
sensors, actuators, and transducers. Mount switches, control devices, coverings, and protection.
 Read standard blueprints
Read and comprehend standard blueprints, machine, and process drawings.
 Perform metal work
Work with metal and iron materials in order to assemble individual pieces or structures.
Self-Check - 9
Written Test
I. Discuss the following question (each 5 point)
1. Explain How To Assemble mechatronics device?
2. Explain how to test Mechatronics device?

Score = ___________
Rating: ____________
Operation Sheet #3 Reassembling and testing Apparatus for return to customer
Operation Title: - Reassembling and testing Apparatus for return to customer

PURPOSE: -
o The trainee’s will be able perform assembling of mechatronics device.
equipment.
Equipment, Tools & Materials: - Maintenance room, Mechatronics device
Procedure: - 1. Reassembling and testing Apparatus for return to customer

 Step 1: Follow safety standards in industrial contexts
 Step 2: Apply soldering techniques
 Step 3: Monitor machine operations
 Step 4: Apply assembly techniques
 Step 5: Align components
 Step 6: Install mechatronic equipment
 Step 7: Ensure conformity to specifications
 Step 8: Remove defective products
 Step 9: Meet deadlines
 Step 10: Clean components during assembly
 Step 11: Read assembly drawings
 Step 12: Maintain mechatronic equipment
 Step 13: Assemble mechatronic units
 Step 14: Read standard blueprints
 Step 15: Perform metal work
.
Precautions:-
Lap Test #3
Name: ____________________________________ Date: ________________________

teacher.
Task 1.
1. Reassembling and testing Apparatus for return to customer
Information Sheet 10 Dealing with unexpected situations
Design for the Unexpected: From Holonic Manufacturing Systems Towards a Humane
Description
Mechatronics Society presents new, even revolutionary, ideas to managing production
and production systems which may fundamentally shift the paradigm of manufacturing systems
design. It provides guidelines for the design of complex systems that can deal with unexpected
disturbances and presents a decentralized control methodology that goes far beyond the traditional
hierarchical control approach that currently prevails.
The benefits are illustrated by a variety of examples and case studies from different fields, with the
book's well-established authors presenting Holonic Manufacturing Systems (HMS) as the framework
for the ‘factory-of-the-future’, and suggesting that the application of biologically inspired control
paradigms can control complex manufacturing systems, and that there are far wider applications for
these systems than pure manufacturing. In addition, the book explores how this multi-agent control
framework can be extended to other fields such as traffic, transport, services, and health care.
Key Features:
 A practical control system architecture that can be uniformly applied to various applications.
 Contains a wide range of sample problems and case studies from different engineering disciplines.
 Provides guidelines for the design of complex manufacturing systems that can deal with
unexpected events.
 Provides a decentralized control methodology that goes beyond the traditional hierarchical control
approach that currently prevails.

Self-Check 10
Written Test
1. Explain what is Unexpected situation in Mechatronics Equipments?
2. What are the key features of unexpected situations of mechatronics device?

Score = ___________
Rating: ____________
Carrying out fault finding repair activities efficiently without
Information Sheet 11
wastage and damage
The 6-point fault finding technique is a method for finding and fixing mechanical operating
malfunctions. These steps include
 collecting evidence,
 analyzing evidence,
 locating faults,
 determining and removing causes,
 rectifying faults and running a systems check. There are certain conditions and actions that
exist in order to execute these six steps. One of these conditions is that safety comes first, and
these steps should not be taken unless it is safe.
In the course of collecting evidence, the investigator has to use the senses of sight, smell, touch and
hearing to know what is wrong with an operating system. Once the collection is complete, an analysis
to consider the validity of the information collection begins. After analysis, the fault in the system is
located with the aid of evidence analysis. Determining or removing the cause of a problem is the next
step to follow the location of a system fault.
Sometimes removing the cause of a system failure is not enough, and the fault must then be rectified.
This usually means fixing the cause of the fault or implementing some kind of maintenance. The last
step in the process is to check the system and make sure it can return to operation.
BASIC STEPS IN FAULT FINDING IN ELECTRONICS
1. COLLECTION OF EVIDENCE: Collecting evidence from the user of emphasis must be much
relevance to the problem rather than a quantity otherwise there is a danger of moving of
essential case in the mass correlated information.
2. ANALYSIS OF EVIDENCE: After collection of evidence, it should be tested into groups in other
to expose any inconsistence which may be presented. It is here that the devoting time to
logical thoughts will save time overall.
3. LOCATION OF FAULTS: General questions which may narrow the areas of possible failure
e.g. If there is no sound from the radio sequence, confirmation is needed that fault actually lies
in the speaker before it is condemned;
Figure 11.1. Location of fault
Fault Location involves:
I. Identify the stage or area that contains the fault.
II. Identify the instrument or component which caused the fault. There may be occasion where a
symptoms identified of faults and related cause e.g. a wire disconnected from a terminal is an obvious
reason for an open circuit and lengthy faults procedures are not necessarily.
4. DETERMINATION AND REMOVAL OF CASE: An important step, e.g. a burnt item in a set
cause by short-circuit rectifier diode, the first line of item must be identified and replaced all
these will be in line if the primary cause of the fault is not removed or changed.
5. RECTIFICATION OF FAULTS: From a simple adjustment of a screw to the replacement of
some major parts of process fault may require maintenance of major of (module) of the
equipment.
Figure 11.2. Rectification of faults

6. CHECKING OF THE SYSTEM: There may be more than one fault checking of the system
must always be carried out because adjustment to are stage or part may be well produce side
effects elsewhere.
Self-Check 11
Written Test
1. Explain the ways to determine mechatronics fault?
2. Explain how to check faults?

Score = ___________
Rating: ____________
Carrying out fault finding repair activities efficiently without
Operation Sheet #4
wastage and damage
Operation Title: - Carrying out fault finding repair activities efficiently without wastage and
damage
PURPOSE: -
o The trainee’s will be able perform Find and repair faults.
equipment.
Equipment, Tools & Materials: - Maintenance room, Mechatronics device
Procedure: - 1. Carrying out fault finding repair activities efficiently without wastage and
damage
 Collection of evidence:
 Analysis of evidence
 Location of faults:
 Determination and removal of case:
 Rectification of faults:
 Checking of the system:
Precautions:-
Quality Criteria:-
 The trainee’s make Assdemble mechatronics device
Lap Test #4
Name: ____________________________________ Date: ________________________
teacher.
1. Carrying out fault finding repair activities efficiently without wastage and damage
LG #68
LO #3 Completion and report fault finding and
Instruction repair
sheet activities
This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics:
 Following OH & S work completion risk control measures and procedures.
 Cleaning work area
 Making written justification for repair to apparatus ( material and components
used)
 Seeking acceptance that the reported fault(s) have been Repaired Product.
This guide will also assist you to attain the learning outcomes stated in the cover
page. Specifically, upon completion of this learning guide, you will be able to:
 Follow OH & S work completion risk control measures and procedures.
 Clean work area
 Make written justification for repair to apparatus ( material and components
used)
 Seek acceptance that the reported fault(s) have been Repaired Product.
Learning Instructions:
Read the specific objectives of this Learning Guide.
1. Follow the instructions described below.
2. Read the information written in the “Information Sheets”. Try to understand what are
being discussed. Ask your trainer for assistance if you have hard time understanding them.
3.Accomplish the “Self-checks” which are placed following all information sheets.
4. Ask from your trainer the key to correction (key answers) or you can request your trainer
to correct your work. (You are to get the key answer only after you finished answering the
Self-checks).
5.If you earned a satisfactory evaluation proceed to “Operation sheets
6. Perform “the Learning activity performance test” which is placed following “Operation
sheets” ,
7. If your performance is satisfactory proceed to the next learning guide,
8. If your performance is unsatisfactory, see your trainer for further instructions or go back to
“Operation sheets”.
Information Sheet 1 Follow OH & S work completion risk control measures
and procedures
1.1. Electrical Safety Principles & Controls

Principles of Electrical Safety and control
 Electricity is different from other forms of hazardous energy, because it is both undetectable
by human senses and potentially immediately fatal upon contact. Since we use electricity every
day and everywhere in our lives, this requires a broad application of specialized equipment
construction methods and safe work practices to prevent serious injuries or death.
 All electrical equipment must be installed and used in accordance with manufacturer’s
instructions. Equipment shall be approved for use (accepted by the Electrical AHJ Standard)
and shall not be modified or used outside of its approval intent. See the Electrical Equipment
Safety Program for more information.
 Sufficient training is required to safely interact with electrical equipment. Operators must be
trained to operate equipment within its design intent and to not defeat engineering controls.
 Personnel who service, modify, repair or build electrical equipment must be able to
recognize the hazards and establish controls to prevent injury. These personnel are called
Qualified Electrical Workers (QEW’s).
 The most fundamental aspect of QEW training is the ability to Test Before Touch. Without
an innate human sense to detect a hazardous condition, QEW’s must understand how to
properly use test equipment to prove an Electrically Safe Work Condition.
 Live repair work is considered extremely hazardous and is generally prohibited. Exceptions
can be made but require detailed justification and approval by senior management.
 Whenever possible, all work performed on equipment will be performed de-energized. In
order to prove and maintain de-energization, QEW’s must follow a strict process to establish an
Electrically Safe Work Condition. This process involves both Lockout/Tagout and Test Before
Touch.
 Some forms of diagnostics require the equipment to be energized while circuit parts are
exposed. Only QEW’s with the proper PPE may perform diagnostics.
 Some combinations of switching, testing and LOTO can involve significant procedural
complexity. In these cases, written work plans are developed, reviewed and approved by
knowledgeable parties in advance and executed with formal procedural compliance.
 Proper body positioning must be an integral part of both everyday work habits and detailed
work planning.
 Every electrical job requires an appropriate level of electrical hazard analysis, work planning,
authorization and direct field supervision that is commensurate with the risk level of the job.
 ISM Steps for Electrical Work:
 Step 1: Define the scope of work
 Step 2: Analyze the hazards
 Step 3: Develop/implement controls
 Step 4: Perform work
 Step 5: Feedback and improve
 Electrical Hazard Analysis
A. If the energized electrical conductors or circuit parts operating above the shock hazard thresholds
are not placed in an Electrically Safe Work Condition, other safety-related work practices, such as to
protect employees who might be exposed to the electrical hazards involved.
B. Such work practices shall protect each employee from arc flash and from contact with energized
electrical conductors or circuit parts, operating above the shock hazard thresholds of directly with any
part of the body or indirectly through some other conductive object.
C. Work practices that are used shall be suitable for the conditions under which the work is to be
performed and for the voltage level of the energized electrical conductors or circuit parts.
D. Appropriate safety-related work practices shall be determined before any person is exposed to the
electrical hazards involved by using both shock hazard analysis and arc flash hazard analysis.
E. The electrical hazard analysis determines the type and rating of shock and arc flash PPE, as well
as approach boundaries to be used.
Developing Controls
A. Depending on the results of the Electrical Hazard Analysis, controls must be selected to minimize
both the risk to the persons performing the work and to persons who may be in the area. Controls are
selected from Section 6. The following are examples of questions to consider when planning the
work.
B. Determine who can perform the work.
 Who will be the Person In Charge?
 What level of QEW is required? '
 Is a Standby Person or Safety Watch required?
C. Determine what level of documentation or authorization is required.
D. Determine how to minimize exposure to the workers.
 Can the arc flash energy be reduced?
 Can parts of the system be locked out?
 Can additional temporary barriers be placed over exposed parts or openings?
E. Determine how to control access to the work area?
 Should attendants be stationed to control access?
F. Determine what other additional controls should apply
The main ways to control a hazard during Completions of work include:

 Elimination (including substitution): remove the hazard from the workplace, or substitute
(replace) hazardous materials or machines with less hazardous ones.
 Engineering Controls: includes designs or modifications to plants, equipment, ventilation
systems, and processes that reduce the source of exposure.
 Administrative Controls: controls that alter the way the work is done, including timing of
work, policies and other rules, and work practices such as standards and operating procedures
(including training, housekeeping, and equipment maintenance, and personal hygiene
practices).
 Personal Protective Equipment: equipment worn by individuals to reduce exposure such as
contact with chemicals or exposure to noise

Self-
Written Test
Check1
1. What are the main ways to control hazard after completion of works
A) Engineering Controls B) Administrative Controls
C) Personal Protective Equipment D) All
2. One of the following Question is asked under developing control of risk Except
A) Determine who can perform the work B) Determine how to control access to the work area
C) Determine how to minimize exposure to the workers D) None
Part two II Explain the following terms (6 points)

1. List and Explain at least four principles of hazardous control?

Score___________
Rating___________
Page 100 of Version -1

Federal TVET Agency TVET program title : Mechatronics and Instrument
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Information Sheet 2 Work area is cleaned and made safe in accordance with established
procedures.
5S Principles
5S activities are to create good working environment through reduction of “Muri”, “Mura”, and “Muda”
 It help to have a basis of strong management of workplace
 What is “Muri”, “Mura”, and “Muda”?
 Muri : overburden, unreasonableness or absurdity.
 Mura : unevenness or inconsistency, primarily with physical matter and the human
spiritual condition.
 Muda : activity which is wasteful or doesn’t add value Source.
Sort
Focuses on eliminating unnecessary items from the workplace
 Categorize equipment, furniture, tool in your working place into the following 3
categories
 Necessary
 Unnecessary
 May not necessary
 This step will also help with the “just in case” attitude.

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Sort : S1
Set
Sustain
S2
S5
Standardi Shine
ze
S3
S4
Figure 2.1. five S principles
Sorting Activity
Equipment, material, tools files, furniture etc. can be categorized based on the frequency of use.

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Figure 2.2. Sorting Activity
Example of sorting
 Place “Red tag” for categorization of items to identify unnecessary items
 Move unnecessary items( broken tools, obsolete jigs and fixtures, scrap and excess
raw material etc.) to central stored area
 Free up valuable floor space (Space utilization)
 Finding abnormality of equipment and tools (Out of order, missing parts etc.)
S2: Set
 “Set” is based on finding efficient and effective storage of necessary items
 Apply “Can see, Can take out, and Can return” philosophy
 This will save time and energy to look for something

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Figure 2.3. Setting Activity
 Labeling , numbering, zoning for clear identification of storage areas to keep

necessary items.
 Set necessary items matching with workflow to minimize unnecessary movement
and transportation time.
S3: Shine
 Cleaning up one’s workplace daily so that there is no dust on floors, machines or equipment.
 It will create ownership and build pride in the workers

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Figure 2.4. Shining Activity
Example of “Shining” activities
 Regular cleaning and maintenance of equipment and tools
 Periodical check for changes in equipment and the service area such as: leaks, vibration,
misalignment, breakage etc.
 IPC activities such as hand hygiene, waste segregation are also part of shine
S4: Standardize
 Maintain an environment where S1 to S3 are implemented in the same manner throughout
the organization
 Give opportunities to employees to take active part in the development of these standards.

120
Figure 2.5. Standardize Activity
Example of “Standardize” activities
 Work instructions, Standard Operating Procedures (SOPs)
 Checklist development and regular usage for SOPs
 Mechanism and format development for ordering supplies, reporting etc
 Color coding for waste segregation
 Standardized common symbols.
S5 : Sustain
 Maintain S1-S4 through discipline, commitment and empowerment
 It focuses on defining a new mindset and a standard in workplace
Example of “Sustain” activities
 Regular progress reporting
 Refresher training

120
 Periodical evaluation of 5S activities with proper advices for continuation and further
improvements
 Appreciation, recognition and awarding on good 5S activities
 Reminder using 5S corner, new letters, good practice sheet etc.
5S is becoming popular for seven solid reasons

 Visible results enhance the generation of more and new ideas
 The workplace gets cleaned up and better organized
 Hospital and office operations become easier and safer
 Results are visible to everyone - insiders and outsiders
 People are naturally disciplined
 People take pride in their clean and organized workplace
 As a result the company’s good image generates more better.
Guidance for Cleaning and Disinfecting of Electrical Equipment

One concern with COVID-19 is that the virus may remain active on surfaces and be transmissible for
days. There is interest in counteracting this risk, but special considerations are needed for disinfecting
electrical equipment [8].
The unprecedented impact of COVID-19 has driven careful attention to the role of our physical
environment in keeping us healthy. Cleaning of all surfaces in homes, schools and public buildings,
commercial locations and workplaces has become a matter of routine. Of particular concern with
COVID-19 is the period of time that the active virus may remain viable on surfaces. This can lead to
an increased risk of transmission. As a result, additional measures are being employed to more
assuredly disinfect these surfaces, some of which have typically only been employed by professionals
in special installations. It is therefore essential that, in an effort to address one safety concern, we are
careful not to introduce another. If not properly performed, cleaning and disinfection of electrical
equipment may result in hazards or unsafe conditions with the equipment. In the interest of providing
guidance on how to safely clean and disinfect electrical equipment, has compiled this list of best
practices:

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 Follow established
What to do:
equipment when possible and wearing any specified personal protective equipment,
e.g., for hands and face.
 Follow the Original Equipment Manufacturer (OEM) instructions for specific cleaning protocols for
equipment or consult the OEM for guidance if such instructions are not available.
 Consult available publications:
 U.S. Occupational Safety and Health Administration COVID-19.
 National Fire Protection Association Standard for Electrical Safety in the Workplace, NFPA
70E
 Disinfecting Guidance for Electrical Equipment, NEMA GD 4-2020
 National Electrical Manufacturers Association (NEMA) COVID-19 Cleaning.
 If a form of liquid or atomized solution is approved for use by the equipment manufacturer, carefully
follow the instructions, using only the specified solution and applicator, taking all specified pre-
application preparations e.g., closing openings before application on the de-energized electrical
equipment. Allow the cleaning/disinfection solution to dry prior to reenergizing the equipment.
 Allow any surfaces that may be hot to cool prior to cleaning.

What not to do:

 Do not spray liquids of any kind into electrical equipment, especially when energized.
 Do not immerse electrical equipment in liquids unless specifically permitted, as indicated by
equipment markings or instructions of the original equipment manufacturer.
 Do not apply liquid or corrosive substances on to electrical equipment unless both the electrical
equipment and substance to be applied are specifically approved for that use. Similarly, do not fog
equipment with disinfectant unless specifically approved for that use. These media may cause
electrical shock or arcing injury hazards. They may also result in degradation of components
or materials in electrical equipment, leading to hazards immediately or over the equipment
life.
 Do not direct ultraviolet (UV) radiation sources at electrical equipment surfaces unless specifically
approved for the purpose, e.g., sunlight resistant (UV-A and UV-B only), and only when professionally

120
applied following UV-safety operating safeguards. Even if the equipment may withstand the
treatment, this process might expose the operator to a radiation hazard (erythema and
optical injury) and shall be approved by a designated safety officer or industrial hygienist
first. UV radiation also may degrade insulating or other materials used in equipment and
produce hazards and should only be used where approved by the original equipment
manufacturer.
 Do not place covering materials on or over surfaces or electrical equipment openings. Such
materials may act as thermal insulation or barriers, causing electrical equipment to overheat.
 Do not remove or deface equipment markings by any cleaning or disinfection action.
Figure 2.6. Warning
Self-Check 2
Written Test
120
1. _______________ Cleaning up one’s workplace daily so that there is no dust on floors, machines
or equipment.
A) Sort B) Clean
C) Standardize D) All
2. ______________ It focuses on defining a new mindset and a standard in workplace
A) Standardize B) Set up
C) Sort D) None
Part two II Explain the following terms

1. List and Explain Guidance for Cleaning and Disinfecting of Electrical Equipment (5)?
2. List Consult available publications (3)?

Score___________
Rating___________

120
Information Sheet 3 Making written justification for repair to
apparatus ( material and components used)
Electrical apparatus means any appliances, fittings, lamps or other apparatus designed for

operation by or in connection with electricity, and any articles or fittings of any kind for use in
connection with any such apparatus.
Hydraulic Repair
PSI Offers the Most Complete Hydraulic Pump, Valve & Motor Repair Services Anywhere, PSI
Repair provides repairs for virtually any hydraulic component, including pumps, motors, valves, servo
valves, actuators, cylinders and power units.
We serve all industries, large or small. Every hydraulic unit received in our facility for repair is completely
disassembled and cleaned for a thorough inspection. Next, all precision fits are checked for tolerances.
Worn, broken, or missing parts are listed for replacement. After a complete evaluation, our customer
service representative will provide you with a competitive quotation for the price of the repair.
After your approval, the unit is cleaned again, tolerances are reverified, and the unit is made ready for
repair. All contact surfaces are reconditioned or replaced, and new seals, bearings and replacement parts
are installed by our highly-trained technicians. When a part is obsolete or beyond repair/reconditioning, our

120
in-house machine shop can reduce cost and create fast turnaround by manufacturing replacements that
meet or exceed OEM specs. After reassembly, the unit is ready to be dynamically tested.
PSI has developed the industry’s most complete line of dedicated open- and closed-loop pump test
stands. We perform tests to ensure that every Repaired Product pump meets or exceeds OEM
specifications, covering pressures up to 5,000 psi and flows up to 150 gpm. All valves and stepping
motors are tested on custom, multi-purpose, electronically-controlled test stands.
PSI HYDRAULIC REPAIR SERVICES INCLUDE:

 Hydraulic Pumps – Piston, Vane, Gear
 Hydraulic Motors– Piston, Vane, Gear
 Feed Panels
 Hydraulic Valve Repairs – Flow Control, Pressure Control, Directional
 Hydraulic Cylinder Repair
 Hydraulic Actuators Repair – Rotary, Linear
 Hydrostatic Drive Repair

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Self-Check 3
Written Test
Part two I Explain the following terms
1. Explain Electrical Apparatus (5)?

2. PSI Hydraulic Repair service (5)?
Score___________
Rating___________

120
Information Sheet 4 Seeking acceptance that the reported fault(s) have been Repaired
Product.
4.1. Repaired Product Approval Process

The Repaired Product will be Submitted for Approval by arranging with the Secretariat/relevant
Programme Manager to make a copy of the repaired product Repaired Product Approval Submission
Form and then emailing REPAIRED PRODUCT Secretariat.
The submitted Repaired Product will be reviewed by the following bodies:
1. The Data Security Foundational Work Stream
2. The Regulatory and Ethics Foundational Work Stream (REWS)
3. A specially convened Repaired Product Review Committee (PRC)
The Steering Committee will be notified by the Secretariat that the Repaired Product has been
submitted.
A questionnaire will be provided featuring questions set by the REWS. This questionnaire will be
provided by the Secretariat and should be filled in and then passed in the Repaired Product Approval
Submission form.
The Repaired Product Review Committee will consist of three members as detailed below nominated
by the submitter.
1. A Work Stream leader from one other Technical Work Stream
2. A member of a third, different, Technical Work Stream
3. A representative of one of the source Driver Projects for the Repaired Product who has been
involved with the Repaired Product Development
The choice of members will be approved by the Engineering Group, subject to any changes
suggested by the Secretariat. The review committee nominates a representative to communicate
back to the Secretariat (this is the technical work stream leader should no nominations be made). The
review committee may give a response of “Accept”, “Reject” or “Changes Requested”. All three

120
members must agree unanimously for the committee to give a positive assessment. The committee
should give this response 1 month after submission of the specification to be reviewed.
It is recommended that the relevant Foundational Work Streams are contacted with any Security,
Regulatory, or Ethical concerns they may have during the development process. The reviews made
at this stage are in addition to those performed during the Proposed phase [9].
A positive assessment is confirmed when the Secretariat receive confirmation from the representative
of each of the reviewing bodies that the review body passes the Repaired Product. If a review body
does not pass the Repaired Product, requested upgrades will be communicated to the submitting
Work Stream Managers. An upgraded Repaired Product can be sent to the reviewers directly. This
cycle can be repeated until the Repaired Product passes the review body requirements.
Once positive assessments have been made by all three bodies, the Repaired Product will be sent to
the REPAIRED PRODUCT Steering Committee for Approval. This must be done two weeks prior to
the Steering Committee meeting at which it is to be assessed.
At the meeting itself, one Work Stream Lead from will present the Repaired Product to the Steering
Committee. The Work Stream lead in charge of the PRC may also be called upon to explain the PRC
processes. If the Steering Committee votes to approve the Repaired Product Product it will be
deemed Approved. If the Steering Committee rejects the Repaired Product Product it will indicate the
reasons for the rejection, and if the Repaired Product Product will require a complete re-submission
through the approval process, or if the issues are minor enough to allow the Repaired Product to be
re-considered in a single expedited review.
Figure 4.1. work flow of repaired product

120
Approving New Versions
Minor and Patch updates to the Repaired Product may take place without the Repaired Product
Review Committee being re-convened.
The approval of a new major version requires a new Repaired Product Approval submission, again
using the provided Repaired Product Proposal Form. Once this process starts the Repaired will be
reviewed by the same bodies as for a first time release.

120
Self-Check 4
Written Test
Part two I Explain the following terms

1. Repaired Product Approval Process (5)?
2. List at least three Repaired Product Review Committee nominated by the submitter (5)?
Score___________
Rating___________

120
Reference
4. 1 “Mechatronics-what is it, why, and how?-and editorial,” IEEE/ASME Trans. on Mechatronics,
1(1), 1-4, 1996.
5. N. Kyura, H. Oho: Mechatronics – An industrial perspective, IEEE/ASME Trans. Mechatron. 1,
10–15 (1996)
6. F. Harashima, M. Tomizuka: Mechatronics – “What it is, why and how?”, IEEE/ASME Trans.
Mechatron. 1, 1–2 (1996)
7. P.A. MacConaill, P. Drews, K.-H. Robrock: Mechatronics and Robotics I (ICS, Amsterdam
1991)
8. S.J. Ovaska: Electronics and information technology in high range elevator systems,
Mechatronics 2, 88–99 (1992)
9. IEEE/ASME Trans. Mechatron., 1(1) (IEEE, Piscataway 1996), (scope)
10. Mechatronics. An International Journal. Aims and Scope. (Pergamon Press, Oxford 1991)
9. https://www.ga4gh.org/how-we-work/ga4gh-product-approval/
10. Shiksha Kendra, 2, Community Centre, Preet Vihar, Delhi-110092 Troubleshooting &
maintenance of electronic equipments
11. https://www.pcmag.com/how-to/how-to-spring-clean-your-electronics
12. fault finding, maintenance and diagnostic skills
13. J. Swift (1667-1745) the Oscilloscope
14.Procedure for Dismantling Waste Electrical and Electronic Equipment (WEEE)
15. Florin Mihai, Maria-Grazie Gnoni, Christia Meidiana, Chukwunonye Ezeah, Valerio EliWaste
Electrical and Electronic Equipment (WEEE): Flows, Quantities, and Management-A Global
Scenario

120
ACKNOWLEDGEMENT
We wish to extend thanks and appreciation to the many representatives of TVET instructors and
respective industry experts who donated their time and expertise to the development of this TTLM.
We would like also to express our appreciation to the TVET instructors and respective industry
experts of Regional TVET Bureaus, TVET College/ Institutes, Bishoftu Management Institute Center,
and Federal Technical and Vocational Education and Training Agency (FTVET) who made the
development of this curriculum with required standards and quality possible.
This TTLM developed on September 2021 at Bin International Hotel, Bishoftu.

120
The trainers who developed the TTLM
No Name Region Level email: tele .Address
1. TESFAHUN AYALEW BGRS /A.Poly A tesfahungps@yahoo.com/0912132308

2. DEREJE ASSEFA BGRS /A.Poly A sharoasse@yahoo.com/0910741157
3. SHAMBEL MOGES Dire dowa A shambelmoges1234@gmail.com/0913883319
4. ISRAEL MOLTOTAL debub A moltotalisraei@gmail.com/0911026069

(wolkete poly)
5. SISAY HAILEMARIAM Arbamench A sisayhailemariam971@gmail.com/0945234339
6 ESUBALEW AMSALU Harer A balewesu@gmail.com/0910644790
7 WONDMAGEGN Akaki kality B Bine-ab@yahoo.com/0913149466

DEREBE Adis.A
8 Melaku Bekele Ambo A Tele phone 0921051772
9 Wekgari Negese Burayu A wekgari@yao.com

Tele phone 0913961682
10 Hailu Fente Adama A Tele phone 0912234810

120

M17 Find and Repair Faults in Measuring and Analysis System V2

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Mechatronics and Instrumentation

Module Title: Find and repair faults in measuring

 Personal protective equipment for Mechatronics

Figure 1.1. Mechatronics safety hat

Figure 1.2. Safety Shoes

Figure 1.4. Safety Glasses

Figure 1.5. Hand Gloves

 Identify the hazards

Note: Satisfactory rating 10 points Unsatisfactory - below 10

 Operation Title: - Identifying and Understanding of OH&S procedures

Name: ____________________________________ Date: ________________________

The main ways to control a hazard during preparations of work include:

Cause, Nature of Fault and Effect of fault

Sr. No. Equipment % of the total fault

Sr. No. Type of Fault % occurrence

1 Line to Ground (L-G) 85

3 Line to Line (L-L) 8

4 L-L-L or L-L-L-G >2

According to nature, the faults are classified as,

 Operation Title: - Obtain Nature of fault

Name: ____________________________________ Date: ________________________

1. How to determine electric faults?

Occupational health and safety manual

Industry/workplace codes of practice

Note: Satisfactory rating 6 points Unsatisfactory - below 6

Title: - Taking Required Material Sources

Procedure: - 1. Workplace guidelines/ workshop manuals

Name: ____________________________________ Date: ________________________

1. Which type of switch we use in stair case wiring?

6.1. Obtaining Tools, Equipment and Testing Device

Figure 6.1. Tools

A millimeter is a measurement tool absolutely necessary. It helps you troubleshooting

Figure 6.2. Millimeter

Figure 6.3. Soldering Stations

A needle-nose pliers is always handy. You should absolutely

Precision Screwdriver Set

Figure 6.7. Tweezers

Figure 6.8. Rotary Tool and Accessories

2. What is the use of Multimeter for mechatronics device?

3) What is the use of Precision screw driver for Mechatronics device?

4) what is the use of Oscilloscope for mechatronics device?

Note: Satisfactory rating 10 points Unsatisfactory - below 10

1.1 Following OH & S risk control measures and procedures.

1. _______is a definite plan of action designed to prevent accidents and occupational

Note: Satisfactory rating above 25 points Unsatisfactory - below 25

2.1 Determining the need to test or measure live.

Self check:1 written test

Note: Satisfactory rating above 20 points Unsatisfactory - below 20

3.1 Checking the apparatus being isolated.

Figure 3.1: Multimeter

 Testing Live vs. Dead

Figure 3.3 ohmmeter use

Figure 3.5: Oscilloscope

Figure 4:1 Fault finding procedures

2. Components are defect. Such a defect cause

Note: Satisfactory rating above 25 points Unsatisfactory - below 25

Operation Title: - Approaching fault finding methodically

Name: ____________________________________ Date: ________________________

5.1 Dismantling Equipment components and parts

Metals Plastics Electronics Other

Name: ____________________________________ Date: ________________________

7.1 Readjusting of Replacing Fault components

Caution - There is a risk of personal injury and equipment damage. To avoid

Name: ____________ Date:

Name: ____________ Date:

Name: ____________ Date:

Name: ____________ Date:

Name: ____________ Date:

Name: ____________ Date:

Name: ____________ Date: