Lesson 1VFD and motor-specific diagnostics: reading drive fault logs, monitoring real-time parameters (speed reference vs actual, torque/load), encoder/feedback checksThis section focuses on VFD and motor diagnostics, including reading fault logs, monitoring real-time parameters, comparing speed reference to actual speed, evaluating torque and load, and checking encoder or feedback devices for accurate closed-loop control.
Reading and interpreting VFD fault and alarm logsMonitoring key real-time VFD parametersComparing speed reference versus actual speedAssessing torque, load, and thermal limitsChecking encoder and feedback signal integrityLesson 2Pneumatic system checks: supply pressure, flow, valve function, actuator stroke/force measurement, and leak detection methodsThis section explains how to evaluate pneumatic circuits, from verifying supply pressure and flow to checking valve operation, actuator stroke and force, and applying systematic leak detection methods to maintain reliable motion and energy efficiency.
Verifying compressor output and supply pressureMeasuring line pressure, drops, and flow demandTesting valve shifting, response, and stickingMeasuring actuator stroke, speed, and forceLeak detection with soapy water and ultrasonic toolsLesson 3Structured diagnostic workflow: symptom collection, recreate fault safely, prioritise likely causes, and hypothesis testingThis section details a disciplined diagnostic workflow, from gathering symptoms and reproducing faults safely to ranking likely causes, planning tests, and confirming root cause, while documenting each step to support repeatable, reliable troubleshooting.
Collecting symptoms and operating historyRecreating faults under controlled safe conditionsPrioritizing likely causes using fault treesDesigning and executing diagnostic testsConfirming root cause and documenting actionsLesson 4Mechanical inspection checklist: visual inspection, belt tension measurement, bearing temperature checks, and alignment verificationThis section presents a mechanical inspection checklist for rotating and linear equipment, covering visual checks, belt tension measurement, bearing temperature trends, and alignment verification to prevent premature wear, vibration, and unexpected failures.
Structured visual inspection of mechanical partsMeasuring and adjusting belt and chain tensionChecking bearing temperature and lubricationVerifying shaft, coupling, and pulley alignmentRecording mechanical findings for trend analysisLesson 5Lockout/Tagout, isolation, and verification: steps, required permits, and safe re-energisation checksThis section explains lockout/tagout principles, isolation methods, verification of zero energy, required permits, and safe re-energisation checks, emphasising practical steps to protect technicians during troubleshooting and post-maintenance testing.
Identifying all hazardous energy sourcesApplying locks, tags, and group lockoutVerifying zero energy and try-out testsPermit-to-work and documentation stepsControlled re-energization and final checksLesson 6Sensor and wiring diagnosis: continuity, insulation resistance, wiring harness inspection, oscilloscope checks for signal quality, and pull-test connectorsThis section covers systematic diagnosis of sensors and wiring, including continuity and insulation resistance tests, harness inspection, connector pull tests, and oscilloscope checks for signal quality, noise, and intermittent faults in industrial environments.
Continuity and resistance checks on circuitsInsulation resistance tests on field cablingInspecting harness routing and mechanical damagePull-testing connectors and terminal tightnessOscilloscope checks for noise and signal qualityLesson 7Electrical measurement plan: where and what to measure (line voltages, phase imbalance, motor current, earth leakage, VFD DC link voltage) and normal rangesThis section defines a stepwise electrical measurement plan for industrial systems, explaining where to place probes, what quantities to record, acceptable ranges, and how to interpret deviations to distinguish normal variation from hazardous faults.
Measuring line and phase-to-phase voltagesDetecting phase imbalance and voltage unbalanceMeasuring motor current and overload indicatorsChecking earth leakage and insulation healthMeasuring and assessing VFD DC link voltageLesson 8Tools and instrumentation: multimeter, clamp meter, oscilloscope, insulation tester (megger), thermal camera, pressure gauge, portable data logger, laptop with VFD softwareThis section reviews key diagnostic tools and instruments, explaining safe use, measurement capabilities, limitations, and selection criteria for multimeters, clamp meters, oscilloscopes, meggers, thermal cameras, pressure gauges, data loggers, and laptops with VFD software.
Selecting and rating multimeters and clamp metersUsing oscilloscopes on power and control circuitsApplying insulation testers without damageThermal imaging for hotspots and loose jointsUsing data loggers and VFD software for trends
