Troubleshooting Flowchart: System Without PLC

This flowchart guides you through diagnosing electrical control system failures in machines that
do not use a Programmable Logic Controller (PLC) for their primary control logic. It focuses on
direct wiring, relays, contactors, and hardwired safety circuits.

START: Machine Not Operating

1.​ Check Main Power Supply

○​ Is there power at the main disconnect (incoming lines)?
■​ NO:
■​ Check building main breaker.
■​ Verify utility power supply.
■​ Inspect supply receptacle/plug for damage or loose connections.
■​ YES: Proceed to Step 2.
2.​ Check Machine Main Fuses / Breaker
○​ Are main fuses blown or main machine breaker tripped?
■​ YES:
■​ Replace fuses / Reset breaker.
■​ Investigate Cause: Look for obvious overloads, short circuits, or
ground faults in the main power distribution.
■​ NO: Proceed to Step 3.
3.​ Check for Lost Phase (for 3-Phase Systems)
○​ Measure voltage across all three phases (L1-L2, L2-L3, L3-L1) at the main
disconnect or machine input terminals.
■​ YES (one or more phases missing/low):
■​ Check incoming supply wiring for open circuits.
■​ Inspect main fuses for a single blown fuse.
■​ Contact utility if issue is upstream of your main disconnect.
■​ NO (all phases present and correct voltage): Proceed to Step 4.
4.​ Determine Scope of Failure
○​ Is the entire machine dead (no lights, no control power, no hum)?
■​ YES: Proceed to Step 5 (Control Power Circuit).
■​ NO (Partial failure, e.g., lights on, but specific function not working):
Proceed to Step 9 (Localized Fault).
5.​ Control Power Circuit (If Entire Machine is Dead)
○​ Check control power input fuses/breaker (e.g., primary side of control
transformer).
■​ NO (blown/tripped):
■​ Replace fuse / Reset breaker.
■​ Investigate Cause: Look for shorts in the control circuit wiring.
■​ YES (OK): Proceed.
○​ Check control transformer output voltage.
 ■​ NO (no output voltage): Replace control transformer.
■​ YES (voltage present): Proceed to Step 6.
○​ Check control power output fuses (e.g., secondary side of control
transformer or power distribution block).
■​ NO (blown):
■​ Replace fuse.
■​ Investigate Cause: Look for shorts in the control circuit after the
transformer.
■​ YES (OK): Proceed to Step 6.
6.​ Safety Circuit Loop (E-Stops, Safety Switches, Interlocks)
○​ Are any E-stops engaged, or safety guards/interlocks open?
■​ YES: Reset E-stops, close guards, ensure interlocks are engaged.
■​ NO: Proceed.
○​ Test entire E-stop/Safety Loop for continuity (typically a series circuit that
de-energizes a control relay).
■​ OPEN CIRCUIT:
■​ Troubleshoot individual E-stop/safety switch/interlock: Check
for stuck buttons, broken wires, misaligned sensors, or tripped
safety relays.
■​ Verify each device in the loop is closed when it should be.
■​ CLOSED CIRCUIT: Proceed to Step 7.
7.​ Operator Input / Control Devices
○​ Is the START button, selector switch, or other primary control device
functioning (e.g., does it have continuity when pressed/selected)?
■​ NO: Replace/repair the faulty control device.
■​ YES: Proceed to Step 8.
○​ Is there any operator feedback (e.g., fault message on a display, indicator
light, alarm)?
■​ YES: Consult machine manual for specific code/message interpretation.
■​ NO: Proceed to Step 8.
8.​ Control Relays / Contactors
○​ Trace the control circuit from the operator input to the main contactor or
motor starter coil.
○​ Is the coil of the main contactor/starter energizing when it should?
■​ NO:
■​ Check for voltage at the coil.
■​ If no voltage, trace back through any intermediate control relays
(e.g., auxiliary relays, timer relays, limit switch contacts) in the
circuit.
■​ Test continuity of all normally open (NO) and normally closed (NC)
contacts in the control path.
■​ Troubleshoot/replace faulty relays or wiring.
■​ YES (coil energizes, but load not running): Proceed to Step 9
(Localized Fault, focusing on the load circuit).
9.​ Localized Fault (Specific Function/Component Not Working)
○​ Identify the specific component or circuit involved (e.g., a single motor, a
solenoid valve, a heating element).
○​ Check local fuses/breakers for that specific circuit.
■​ NO (blown/tripped):
■​ Replace fuse / Reset breaker.
■​ Investigate Cause: Look for overload or short in that specific load
circuit.
■​ YES (OK): Proceed.
○​ Check for voltage at the component's terminals when it should be
operating.
■​ NO:
■​ Trace back wiring from the component to its power source (e.g.,
main contactor, auxiliary contactor, direct power feed).
■​ Check associated relays/contactors/switches that control this
specific component.
■​ Verify continuity of wiring.
■​ YES: Proceed to Step 10.
10.​Load / Motor Protection (Overload Relays)
○​ Is the overload relay (for motors or other high-current loads) tripped?
■​ YES:
■​ Reset the overload.
■​ Investigate Cause:
■​ Mechanical binding/excessive load on the motor.
■​ Motor fault (e.g., winding short, bearing failure).
■​ Incorrect overload setting.
■​ Phase imbalance.
■​ Allow time for motor to cool if thermal overload.
■​ NO: Proceed to Step 11.
11.​Check Component Itself
○​ For Motors:
■​ Measure winding resistance: Look for open or shorted windings.
■​ Check bearings: Listen for noise, feel for excessive heat/vibration.
■​ Verify mechanical connection: Is the shaft free to turn?
○​ For Solenoids/Coils:
■​ Measure coil resistance: Look for open coil (infinite resistance) or
shorted coil (very low resistance).
■​ Check for plunger movement: Is it stuck?
○​ For Heating Elements:
■​ Measure resistance: Look for open circuit.
○​ Is the component faulty based on tests/inspection?
■​ YES: Replace the component.
■​ NO: Proceed to Step 12.
12.​General Checks & Environmental Factors
 ○​ Physical Damage:
■​ Inspect all wiring, terminals, components, and enclosures for visible
damage (chafing, cuts, burns, cracks).
■​ YES: Repair or replace damaged parts.
■​ NO: Proceed.
○​ Water Damage / Contamination:
■​ Look for evidence of moisture, corrosion, dust, or foreign material
inside enclosures or on components.
■​ YES: Clean, dry thoroughly, repair/replace affected parts. Ensure proper
sealing/environmental protection.
■​ NO: Proceed.
○​ Loose Connections:
■​ Physically check and tighten all terminal screws, wire nuts, and
cable connections. Loose connections can cause intermittent faults,
overheating, and voltage drops.
■​ YES: Tighten/repair.
■​ NO: Proceed.
○​ Heat / Smell:
■​ Feel components and wiring for excessive heat. Smell for burning
insulation.
■​ YES: Identify the source of overheating, repair or replace the affected
component/wiring.
■​ NO: Proceed.
13.​Consult Manual / Advanced Diagnostics
○​ If the issue persists, consult the machine-specific manual for detailed
schematics, sequence of operations, and advanced troubleshooting
guides.
○​ Consider using specialized test equipment (e.g., megohmmeter for insulation
testing, thermal camera for hot spots, oscilloscope for signal integrity).
○​ Consider intermittent fault: Monitor the system with a data logger or observe
during operation for transient conditions.

END: Issue Resolved or Escalated to Engineering/Specialist