M08 Domestic Appliance

ELECTRICAL/ELECTRONICS
EQUIPMENT SERVICING
Level – II
Based on April 2022, Curriculum Version 1
Module Title: Maintaining and Repairing Electric

Domestic Appliance
Module Code: EIS EEES2 M08 0322
Nominal duration: 80 Hours
Prepared by: Ministry of Lobar and Skill
August, 2022
Addis Ababa, Ethiopia

Table of Contents
Acknowledgement......................................................................................................... 3
Acronyms ....................................................................................................................... 4
Introduction to the Module ........................................................................................... 5
Unit one: Set up the unit, tools, equipment, and workstation ..................................... 6
1.1. Workplace maintenance .............................................................................. 7
1.2. Necessary tools and test equipment ............................................................ 8
1.3. Set up and organize equipment’s .............................................................. 10
1.4. Repair & maintenance equipment ............................................................. 12
1.5. Service manuals and service information .................................................. 15
Self-check-1 ................................................................................................................. 17
Operation sheet-1 ........................................................................................................ 19
Lap Test -1 ................................................................................................................... 20
Unit two: Diagnose the unit's faults .......................................................................... 21
2.1. Electronically-controlled domestic appliances ............................................... 22
2.1.1. Driers, Blender, coffee maker and Toaster ................................................. 24
2.1.2. Onion chopping and Coffee grinding .......................................................... 33
2.2. Pre-testing procedure ................................................................................ 41
2.3. System Defect/Fault Symptoms ................................................................ 42
2.4. Troubleshooting procedures ...................................................................... 48
2.5. checking and isolating Circuits .................................................................. 50
2.6. Documenting Results of diagnosis and testing .......................................... 53
2.7. Customers service ..................................................................................... 54
Operation sheet-2 ........................................................................................................ 57
Lap Test-2 .................................................................................................................... 58
Unit Three: Unit maintenance/repair.......................................................................... 59
3.1. Personal protective equipment ..................................................................... 60
3.2. Electro-static discharge (ESD) protection ...................................................... 61
3.3. Replacing Defective parts/components ..................................................... 66
3.4. Cleaning of unit.......................................................................................... 73
Self-check – 3 .............................................................................................................. 78
Operation sheet-3 ........................................................................................................ 79
Lap Test-3 .................................................................................................................... 80
Unit Four: Unit repair test ........................................................................................... 81
4.1. Assembly of repaired units ............................................................................ 82
4.2. Reassembled unit final testing and cleaning.............................................. 82
4.3. Service completion procedures and documentation .................................. 84
4.4. Waste Materials Disposal .......................................................................... 85
Self-check-4 ................................................................................................................. 90
Operation sheet-4 ........................................................................................................ 91
Lap Test-4 .................................................................................................................... 92
Reference ..................................................................................................................... 93
Page 2 of 94 Author/Copyright Maintaining and Repairing Training module Version -1

Ministry of Labor and Skills electric domestic appliance August, 2022
Acknowledgement
Ministry of Labor and Skills 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 Teaching, Training and Learning Materials (TTLM).

Acronyms
AC..……………………………. Alternating current

DC……………………………… Direct current
OHS ………………………………Occupational health and safety
LAP ……………………………… learning assistance program
LED………………………………light emitting diode
PCB………………………………printed circuit boar
ESD………………………………electrostatic discharge
DMM………………………………digital mustimeter
VOM………………………………volt ohm meter
GFCI ……………………………. Ground Fault Circuit Interrupter

Introduction to the Module
In Electrical/electronic equipment servicing filed; the Maintaining and repairing electric

domestic appliance project helps to know (Toaster, flat iron, pressure cooker, Blender, coffee
maker and waffle maker, Onion chopping, Coffee grinding). It includes diagnosing faults,
dismantling, re-assembling, testing and preparing reports Connect and terminate electrical wiring
Systems.
This module is designed to meet the industry requirement under the Electrical/electronic equipment
servicing occupational standard, particularly for the unit of competency: Maintaining and
repairing electric domestic appliance.
Module units
 Set up the unit, tools, equipment, and workstation
 Determine the unit's faults
 Unit maintenance/repair
 Unit repair test
Learning objectives of the Module
At the end of this session, the students will able to:
 Prepare unit, tools, equipment and workstation
 Diagnose faults of the unit
 Maintain/repair the unit
 Test repaired unit
Module Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described below.
3. Read the information written in the information Sheets
4. Accomplish the Self-checks
5. Perform Operation Sheets
6. Do the “LAP test”

Unit one: Set up the unit, tools, equipment, and workstation
This learning unit is developed to provide the trainees the necessary information regarding the
following content coverage and topics:
 Workplace maintenance
 Necessary tools and testing equipment
 Set up and organize equipment’s
 Repair & maintenance equipment
 Service manuals and service information
This unit 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:
 Prepare workplace for maintenance
 Prepare necessary tools, and test instruments
 Set and arrange equipment’s
 Verify repair & maintenance equipment
 Require service manuals and service information

1.1. Workplace maintenance
In every electronic work, it is a must to prepare first the necessary tools, materials, equipment
and well organized workplace needed as well as the information. Some of The following list of
tools, materials, and equipment/but not limited/ are needed in maintaining and repairing domestic
electronically controlled equipment/appliances and a sample of workshop organization shown
below.
Figure 1.1 workshop organization

DUT – This large DUT prevents you from using a product safety enclosure.
A Instead, other precautions
must be taken to ensure a safe testing station.
B The Hipot Tester – tester used to test the DUT.
C Test Operator.
High Voltage Insulation Mat – This isolates you from ground which provides
D an additional means of
protection when operating high voltage equipment.
Signal Tower Light – gives an indication as to the status of the testing area. A
green light indicates the
E Hipot tester is not outputting high voltage and the test area is safe. A red light
indicates that the Hipot
tester is active and to stay clear of the test area.
Emergency Stop Button – An E-stop button is located on the perimeter of the
test area. In the event of
F an emergency, someone outside the test area can hit the E-Stop button to
immediately cut off power
to the entire test station.
Warning Signs4 – Mark the testing area with clearly posted signs that read:
G DANGER-HIGH VOLTAGE
TEST IN PROGRESS. UNAUTHORIZED PERSONNEL KEEP AWAY.

Sectioned Off Test Area – Since the size of the DUT restricts the use of an
enclosure, this test area is
sectioned off by a mesh fence to keep unauthorized personnel away from the
H testing station. NEC
(National Electric Code) and NFPA (National Fire Protection Agency)5
stipulate that any unqualified
workers shall not come within 10 feet of an EXPOSED energized circuit.
Table 1.1 workshop organization
1.2. Necessary tools and test equipment

Preparing tools, test instruments: same of are listed below but not limited
Figure1.2 tools, test instruments

1.2.1. Personal Protective Equipment
Personal Protective Equipment (PPE) is defined in the Occupational Safety and Health
Administration (OSHA) as a tool used to protect workers from injury or illness caused by having
contact with the dangers (hazards) in the workplace, whether they are chemical, biological,
radiation, physical, electrical, mechanical and other. Exposures to hazards are reduced using
PPE.
The types of Personal Protective Equipment
Personal Protective Equipment can be classified according to target organs potentially affected of
the risk of danger. Identification of hazard and risk assessment of a job, process and activity must
be done first before deciding which type of PPE to be used.
Table 1.2 Personal Protective Equipment

Figure 1.3 Personal Protective Equipment
1.3. Set up and organize equipment’s
1.3.1. Setting Workplace for repair

Building maintenance is work undertaken to keep, restore or improve every facility i.e.
every part of a building, its services including maintenance operations to a currently
acceptable standard and to sustain the utility and value of the facility.
The objective of setting workplace is: -
(i) To preserve machinery, building and services, in good operating condition.
(ii) To restore it back to its original standards, and
(iii) To improve the facilities depending upon the development that is taking place in the
building engineering.

1.3.2. Setting up a Safe Workstation
One of the best ways to prevent injury is to ensure that the test station is set up safely and
securely. Test stations can be setup with or without direct protection depending on your
requirements. Direct protection means that the operator cannot physically come into
contact with an energized DUT/device under test/ while a test is running.
Sample Proper Arrangement and storage of tools and equipment
Figure 1.4 tools and equipment
Figure 1.6 Safe Workstation

Station with protection against electric shock.
1.4. Repair & maintenance equipment

Maintenance recommendations are based on industry standards and experience in Reclamation
facilities. However, equipment and situations vary greatly, and sound engineering and
management judgment must be exercised when applying these recommendations. Other sources
of information must be consulted (e.g., manufacturer=s recommendations, unusual operating
conditions, personal experience with the equipment, etc.) in conjunction with these maintenance
recommendations.

Types of maintenance
Maintenance is work done to correct, reduce, or counteract wear, failure, and damage to
equipment. Maintenance of electrical and electronic equipment is divided into two main
categories: PREVENTIVE (routine) and CORRECTIVE maintenance.
 Preventive maintenance: - consists of mechanical, electrical, and electronic checks to

determine whether equipment is operating properly. It also consists of visual inspections
of cabling and equipment for damage and to determine if lubrication is needed.
 Corrective maintenance: - isolates equipment failure by means of test techniques and

practices; it also replaces defective parts and realigns or readjusts equipment to bring it
back to proper performance
Maintenance and test procedures
Maintenance activities fall into three general categories:

A. Routine Maintenance: - Activities that are conducted while equipment and systems are in
service. These activities are predictable and can be scheduled and budgeted. Generally, these are
the activities scheduled on a time-based or meter-based schedule derived from preventive or
predictive maintenance strategies. Some examples are visual inspections, cleaning, functional
tests, measurement of operating quantities, lubrication, oil tests, and governor maintenance.
B. Maintenance Testing: - Activities that involve using test equipment to assess condition in an
offline state. These activities are predictable and can be scheduled and budgeted. They may be
scheduled on a time or meter basis but may be planned to coincide with scheduled equipment
outages. Since these activities are predictable, some offices consider them “routine maintenance”
or “preventive maintenance.” Some examples are governor alignments and balanced and
unbalanced gate testing.

C. Diagnostic Testing: – Activities that involve using test equipment to assess the condition of
equipment after unusual events, such as equipment failure/ repair/replacement or when
equipment deterioration is suspected. These activities are not predictable and cannot be
scheduled because they are required after a forced outage. Each office must budget for these
events. Some examples are governor troubleshooting, unit balancing, and vibration testing.
Maintenance procedures
 Prepare necessary tools, test instruments and personal protective equipment in line
with job requirements
 Acquire service manuals and service information required for repair

/maintenance as manufacturer’s specifications
 Conduct complete check-up of electronically-controlled domestic appliances
 Document the identified defects based on check-up conducted

1.5. Service manuals and service information
Service manual is the full written information provided by the manufacturer regarding the
equipment. This service manual usually accompanies the equipment at time of purchase. A
service manual consists of some or all of the f/f
1. Safety & precautionary measures during dissembling
2. Dismantling or blow-up diagram
3. Block diagram of the equipment
4. Circuit diagram
5. PCB lay out
6. Parts-list
7. Service manual/schematic diagram/parts list
8. Operating instructions/User’s/Owner’s manual
9. Component data sheet/handbook
Service information
Record all information during maintaining/repairing electronically-controlled domestic
appliance.
This may include but not limited to:
1. Job report sheets 2. Job order 3. Bill of materials 4. Customer index 5. Service
flowchart 6. stock and inventory record 7. Requisition slips (for acquisition of parts)
supplier index
Directions: Provided with the defective domestic appliance use Maintain and Repair
Form to gather and document the information about the appliance at hand. Follow the
procedures below:
Resources:
Domestic appliance: --------------------------
Receiving/Check-up Form
Procedure:
1. Conduct an initial interview to the owner of the appliance.
 Ask what the problem is.
 Request for the details of the problem (how does it happen/since when/ nature of

the problem)
2. As serviceman, you must confirm the problem/ complain.
3. Make an initial inspection/ testing of the appliance.

 Physical appearance
 Operating controls
 Power cord etc.
4. Take note of the information gathered and observed.
5. Accomplish Receiving and Repair Form.
Receiving and Repair Form
Customer’s name: ________________________________________________________
Address:
__________________________________________________________________
Product/ Brand name: ___________________________________________________
Serial no:
________________________________________________________________
Complain: _______________________________________________________________
____________________________________________________________________
Electric………… Checklist (e.g. Refrigerator, washing machine, flat iron)
Part of equipment condition
good defective
Power cord
Power switch
customer’s Signature______________________ Date Repaired: ______________

technician’s Signature______________________ Date Checked: ______________

Self-check-1
Test-I Choose
Instruction: For the Following Questions You Are Given Four Alternatives Then Choose the
Correct Answer and circle.
1, Activities that involve using test equipment to assess the condition of equipment after unusual
events (3 pt each)
A, Routine Maintenance B, Diagnostic Testing C, Maintenance Testing D, all
2, Isolates equipment failure by means of test techniques and practices. (3 pt each)
A Diagnostic Testing B, Corrective maintenance C, Preventive maintenance D,
Maintenance Testing
3, consists of mechanical, electrical, and electronic checks to determine whether equipment is
operating properly. (3 pt each)
A Diagnostic Testing B, Corrective maintenance C, Preventive maintenance D,
Maintenance Testing
4, The objective of setting workplace is (3 points)
A, To preserve machinery, building and services, in good operating condition.
B, To restore it back to its original standards, and
C, To improve the facilities depending upon the development that is taking place in the
building engineering. D, all
5, A service manual consists of some or all of the f/f (3 points)
A, Safety & precautionary measures during dissembling
B, Dismantling or blow-up diagram
C, Block diagram of the equipment
D, All
6.Record all information during maintaining/repairing electronically-controlled domestic
appliance. This may include but not limited to: (3 points)
A, Job report sheets B, Job order C, Bill of materials D, Block diagram of the
equipment E, all
7, Service manual is the full written information provided by --------------. (3 points)
A, manufacturer B, Technician C, seller D, teacher

Test II: short Answer writing
Instruction: Identify the tools, equipment and materials in maintaining and repairing a domestic
equipment’s and Write your answers on a separate sheet. (10 pt each)
1. ---------------------- 2. -------------------3. ---------------------4. ---------------------5. --------------

6.-----------------------7. -----------------------8. --------------------9. ----------------------10-------------
Test III: Say true or false

1, one of the best ways to prevent injury is to ensure that the test station is set up safely and
securely. A, True B, False
2, Test stations can be setup with or without direct protection depending on your requirements.
A, True B, False
Note: Satisfactory rating – above 60% Unsatisfactory - below 60%

You can ask you teacher for the copy of the correct answers

Operation sheet-1
Operation Title: Techniques for Preparing Workplace/equipment for maintenance

Purpose: To Prepare Workplace/equipment for maintenance
Instruction: Using the figure below and given equipments to Workplace/equipment for
maintenance. You have given 30Minut for the task and you are expected to Preparing
Workplace/equipment
Tools and requirement
 Multimeter
 Utility knife/stripper
 Wrenches (assorted)
 Allen wrench/key
 Screws (assorted)
 Pliers (assorted)
Procedures:
1. Prepare necessary tools, test instruments and personal protective equipment in
line with job requirements.
2. Acquire service manuals and service information required for repair
/maintenance as manufacturer’s specifications.
3. Conduct complete check-up of electronically-controlled domestic appliances.
4. Document the identified defects based on check-up conducted
Quality Criteria: use service manuals and service information for maintenance.
Precautions: use the given necessary tools, test instruments.

LAP Test -1
Name: __________________________ Date: ____________
Time started: ____________________ Time finished: _______________
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 4 hours.
Task 1. Preparing Workplace/equipment for maintenance
Task 2 Verifying maintenance history with the company procedures
Task3 Acquiring Service manuals and service information
Task4 Setting Workplace for repair
Task 5 Preparing tools, test instruments and personal protective equipment

Unit two: Diagnose the unit's faults
 Electronic-controlled domestic appliances
 Procedure for pre-testing
 System defect/fault symptoms in domestic equipment
 Troubleshooting procedures implementation
 Circuit testing and isolation
 Recording the outcomes of diagnostic and testing procedures
 customer service advice/information
This unit 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:
 Identify electronically-controlled domestic appliances
 Pre-testing procedure
 Identify System defect/fault of domestic equipment symptoms
 Implement troubleshooting procedures
 check and isolate Circuits
 Document results of diagnosis and testing procedures
 Advising/informing Customers service

2.1. Electronically-controlled domestic appliances
Electronic control is also referred as electronic regulation that is done to an appliance, situation
or load by electronic devices. Domestic appliances are commonly controlled directly or manually
using electrical switches and timers. Some of these electronic controlled domestic appliances are
Toaster, flat iron, pressure cooker, Blender, coffee maker and waffle maker, Onion chopping,
Coffee grinding
In electronic devices, transformer is commonly used not just to reduce the supply voltage
(220VAC) but also to isolate the load from the power source.
A. Step-up Transformers
• A transformer in which the secondary voltage is greater than the primary voltage is
called a step-up transformer
• The ratio of secondary voltage (Vsec) to primary voltage (Vpri) is equal to the ratio of
the number of turns in the secondary winding (Nsec) to the number of turns in the
primary winding (Npri) Vsec/Vpri = Nsec/Npri
Figure 2.1 step up transformer
B. Step-Down Transformer
• A transformer in which the secondary voltage is less than the primary voltage is called
a step-down transformer
• The amount by which the voltage is stepped down depends on the turns ratio• The turns
ratio of a step-down transformer is always less than 1
Figure 2.2 Step Down Transformer

The Transformer as an Isolation Device
• Transformers are useful in providing electrical isolation between the primary circuit and the
secondary circuit because there is no electrical connection between the two windings.
 In a transformer, energy is transferred entirely by magnetic coupling DC Isolation.
• A transformer does not pass dc; therefore, a transformer can be used to keep the dc voltage on
the output of an amplifier stage from affecting the bias of the next amplifier.
• The ac signal is coupled through the transformer between amplifier stages.
Figure 2.3 isolation transformer
Power Line Isolation

• Transformers are often used to electrically isolate electronic equipment from the ac power line
Figure 2.4 Testing of transformer

2.1.1. Driers, Blender, coffee maker and Toaster
Blender
Blender is one of the important home/domestic equipment widely used in homes and restaurants
for food mixing. Commonly known as mixer.
Figure 2.5 Blender
1. Before you begin blending, please review all instructions of the electronic manual carefully.
Familiarize yourself with all warnings, warranty issues, what could avoid the warranty, would
could cause damage to the blender and/or injury to you or bystanders, and anything else in
order to perform appropriate blender blade and container maintenance.
2. Keep the blender, blade, and/or container out of reach of children who might be too
young to safely operate the blender.
3. No, the blade cannot be stopped by hand during operation. Most obstructions won’t stop
the blade from turning. Please do not ever put your hand and/or any part of your limbs into the
container during blending operation.

4. To be safe, if you have to remove an object from the blade and/or container, remove the
container from the blender base and only then stick your hand into the inside of the container to
remove that object (and do that at your own risk – blades are sharp and could cut your fingers).
5. Use the appropriate capacity that it can hold which is leveled.
Figure 2.5 front and top description
On the top please note Blender details which are important to know and understand for your
effective and safe blending operation. In order to blend safely and effectively without spilling or
a mess associated to blending, always blend only with ingredients or content in the container and
the appropriate lid and cap on top of the blender base and container.

OMNI V Blender Operating SPEED Control Keypad
The OMNI Keypad, as seen to the above, is equipped with 3 speeds: Low, Medium, and
High Speed push touch-key buttons. The electronic and waterproof keypad also features 35, 60,
and 90 second timer settings, and also a Pulse Button. Just push your selection until you feel a
little resistance.
A. In order to turn on the blender:
1. First plug in the power cord into your 110 Volt outlet if you bought a 110 Volt Blender,
or into a 220-volt outlet if you bought a 220-volt blender. The operating circuit amperage
should be a minimum of 15 amps with the 110-volt power supply and 8 amps with the
220-volt power supply.
2. Switch the ON/OFF switch to the very left in Red to ON until you see the light on the
ON/OFF Main Power Switch.
3. Then select your speed or timer setting, or pulse. If you selected the Pulse button, the
blender will only operate for as long as you hold down the PULSE button. If you use any
of the TIMER or SPEED selections, you need to push once and then let go. This will
cause the Blender Blade to run according to the selection you have made. If you want to
prematurely turn off your blending cycle, you can push any of the operating functions
(buttons) including the Main Power Switch and the PULSE button once. If you push any
of the functional operating switches twice while blending, you are turning off the cycle
with the first time push and you will turn it back on in the new function when pushing it
the second time .
Before operating your blender, make sure that there is no water on the blender base, on
top of the container cushion, or near the bottom of the blender base housing Power
Plug/Cord Storage Area and Rubber Feet. Although the OMNI Blender is equipped with
a seal/gasket on top under the housing where the drive socket is, it still could vacuum in /
suck in water into the inside of the motor housing through any of its openings for venting.
Water will obviously cause damage to the motor and/or any of the electronic switches.

If during the blending your container splashes (this can happen at times if you put too
much watery liquid over 50 oz in the container - It won't happen with creamy smoothie or
soup and sauce blending content)- make sure you have a towel close by to quickly wipe
off and absorb any water around and/or on the blender. Never submerge the blender into
water or partially cover it. Electrical shortening and shock (bodily harm) could be the
result...
Also, make certain that the vent-in and vent-out areas (to keep the motor cool) on the
blender are never covered or obstructed. They are on the bottom and on the sides. Besides
that this would void the warranty, the blender could stop working, overheat, etc...
(Actually the Safety Switch / Overload Switch on the back of the blender is also a switch
that prevents the motor from overheating).

coffee maker
There are different types of coffee maker machine. One is gravity filter coffee maker
Gravity filter coffee maker
Figure 2.6 coffee maker machine

• This appliance can be used by children aged from 8 years and above and persons with reduced
physical, sensory or mental capabilities or lack of experience and knowledge if they have been
given supervision or instruction concerning use of the appliance in a safe way and understand the

hazards involved. Children shall not play with the appliance. Cleaning and user maintenance
shall not be done by children unless they are older than 8 and supervised.
• Make sure your electricity supply matches the voltage shown on the appliance.
• Ensure all packaging materials and any promotional labels or stickers are removed from the
appliance before the first use.
• Always inspect the appliance before use for noticeable signs of damage. Do not use if damaged
or has been dropped.
• Do not use this appliance if the lead is damaged
• Always use the appliance on a dry, level, heat resistant surface.

• Unplug from the mains when not in use and before cleaning. Allow to cool before cleaning the
appliance. To disconnect, turn the socket to “off “and remove the plug from the mains socket.
• Do not use any accessories or attachments with this appliance other than those recommended
by Lakeland.
• To protect against fre, electric shock or personal injury, do not immerse cord, plug or unit in
water or other liquids. Do not use near the sink.
• Do not leave the lead hanging over the edge of a kitchen table or worktop. Avoid contact
between the lead and hot surfaces.
• For indoor use only.
• For domestic use only.
• This appliance should be used for preparation of drinks as described within the instructions for
use that accompany it.
• Always ensure that your hands are dry before removing the plug from the mains socket. Never
pull the plug out of the mains socket by its lead.
• To avoid injury or possible fre, do not cover the appliance when in use.
• Do not connect this appliance to an external timer or remote control system.
• An extension cable may be used with care. The electrical rating of the cable should be least as
great as the appliance. Do not allow the cable to hang over the edge of the worktop or touch any
hot surfaces.
• This appliance complies with the basic requirements of Directives 04/108/EC (Electromagnetic

Compatibility) and 06/95/EC (Safety of Domestic Electrical Appliances).
• WARNING: A cut off plug inserted into a 13amp socket is a serious safety (shock) hazard.
Ensure the cut off plug is disposed of safely.
• CAUTION: The plastic bags used to wrap this appliance or the packaging may be dangerous.
To avoid risk of suffocation, keep these bags out of reach of babies and children. These bags are
not toys.
• Do not place the appliance on or near a gas or electric oven, or any hot surfaces.
• Do not move the appliance while it is switched on.
• Only use the carafe with this appliance, it must never be used on a hob or in a microwave. Do
not put the hot carafe down onto a wet or cold surface. Do not use the carafe if it is damaged.
Ensure the carafe is securely on the base before switching on the appliance.
• Ensure the carafe lid is securely in place when using the Gravity Filter Coffee Maker and when
pouring coffee. Do not use force when putting the lid on the carafe.
• The water tank must be flled with water to at least the ‘¼ litre/2 cup MIN’ mark, before it is
switched on. Do not fll beyond the ‘1¼ litre/10 cup MAX’ mark, or the appliance may spit
boiling water.
A. INSTRUCTIONS FOR USE

• Fill the carafe with clean cold water, to the amount you require using the cup measurements
on the side.
• Always fll beyond the ‘¼ litre/2 cup MIN’ mark, but do not exceed the ‘1¼ litre/10 cup
MAX’ mark on the carafe and the water tank, or the appliance may spit boiling water.
• Lift the water tank lid and pour in the water from the carafe.
figure 2.7 carafe with cold water

• Put the water tank lid back onto the water tank with the ‘front’ mark facing you and the vents
towards the back of the machine. Ensure the water tank lid is fully closed.
Figure 2.8 openings water tank
• Slide the brewer handle to the left in the direction of the arrow to open the brewer, and remove
the filter basket and permanent filter.
• Add your coffee to the permanent filter, or alternatively use a paper filter. For each cup of
coffee (125ml), add 7.5 grams of ground coffee into the filter, or one level measuring spoon. Do
not fall beyond the ‘MAX’ mark inside the permanent filter.
Figure2.9 powdered coffees into filter
• Place the filter into the filter basket.

• Place the filter basket back inside the filter holder, it will only ft one way, with the handle
folded forwards so it lies flat.
• Close the brewer by sliding it to the right until the handle clicks into place at the front of the
coffee maker.
• Plug in the coffee maker and switch it on at the socket.

Figure 2.10 Plug in the coffee
• Slot the empty carafe onto the hot plate.

• The pourer is on a spring, which will move upwards when the jug is put onto the hot plate. The
hole in the carafe lid will line up with the pourer when the carafe is in position on the hot plate,
so the coffee can filter straight into the carafe. Ensure the carafe is securely on the base.
Figure 2.11 coffee brewing
• Press the on/off button, it will illuminate and the water in the tank will start to heat up.
• Once boiled, the water will automatically start to filter through the brewer into the carafe.
• Do not remove the carafe from the hot plate during brewing.
• The hot plate will keep your coffee warm for around 40 minutes after brewing has started, then
automatically switch off.
• Press the ON/OFF button to turn the coffee maker off to stop the coffee brewing mid cycle;
when the carafe has been emptied; or when you no longer want to keep the coffee warm. Always
remove the used coffee filter from the appliance immediately
after brewing.
• During brewing, condensation will form underneath the water tank lid. When brewing has
finished, take off the lid to help the condensation evaporate and stop it running back into the
water tank. Take care, steam/water could be hot when you take of the lid.

2.1.2. Onion chopping and Coffee grinding
 Coffee grinding
The coffee grinder is designed to be used only for grinding roasted coffee beans and dis-pensing
the ground coffee obtained from the grinding process. For safety reasons, it should never be used
for any other purposes.
 Improper use of the machine for operations other than the above can constitute a safety
risk to persons and to the equipment.
 Never work the machine with wet hands or naked feet.
 Avoid wetting the outer surface of the grinder. If it does get wet during operation, or even
when not operating, unplug it immediately and dry it thoroughly.
 It is very important for your safety to make sure before turning the coffee grinder on that
the hopper (2) is well-attached to the adjustment platen (4) by means of the lock screws
(3). If not, when the coffee grinder is turned on, the grinding teeth starts to spin and can
be easily touched with the fingers.
 Never run the coffee grinder without the hopper (2) correctly in place and attached by the
locks crews (3).
 Do not run the grinder continuously for more than 30 minutes at a time
 When filling the hopper (2), make sure no objects (nectie, scarf, hair jeweler etc.)
accidentally fall into the hopper or the adjustment platen.
 A thermal protector prevents overheating of the electric motor coils, cutting off power
when the temperature rises above the the maximum admissible level due to a malfunction
like continued blockage of the rotor

Figure 2.12 Coffee grinding

Table 2.2 Troubleshooting Coffee grinding
 A clothes iron
A clothes iron, also called a flatiron or simply an iron is a small appliance: a handheld piece of
equipment with a flat, roughly triangular surface that, when heated, is used to press clothes to
remove creases/irregular shapes. It is named for the metal of which the device is commonly
made, and the use of it is generally called ironing. Ironing works by loosening the ties between
the long chains of molecules that exist in polymer fiber materials. With the heat and the weight
of the ironing plate, the fibers are stretched and the fabric maintains its new shape when cool.
Some materials, such as cotton, require the use of water to loosen the intermolecular bonds.
Many materials developed in the twentieth century are advertised as needing little or no ironing.
 Flat iron/clothe iron-is the name of a small home electrical appliance.
 Ironing is the process of using the device /straighten the cloth.
Parts and Features
1. Automatic Shutoff Reset Button/Light*
2. Spray and Blast Buttons
3. Adjustable Steam Knob Dial
4. Water Fill Cover
5. Spray Nozzle
6. Water Window
7. Temperature Control
8. Soleplate
9. Heel Res
10. Power Light
11. Cord

Main parts and their use
 Sole Plate: The sole plate, or base, of the iron is flat and roughly triangular in
shape. The modern metal of choice for sole plates is aluminum coated with a non-
stick material. The sole plate, which is heated and applied to wrinkle clothing, allows
a user to concentrate on small areas that need extra attention.
 Thermostat: Modern flat irons have thermostats built into them to let a user
control the sole plate temperature. More delicate/filmy or smooth fabrics require little
heat while heavy duty fabrics require much more heat. The thermostat is essentially a
spring with power contacts on the end mounted on a metal post. Electricity passes
through the contacts to heat the sole plate.
Figure 2.13 Flat iron/clothe iron

There are different models of steam irons
 Water Reservoir: The water to create the steam is stored in the reservoir. When
a user presses a button on the iron to release steam, the water is superheated
and released as steam.

 Handle: Manufacturers generally make modern steam iron handles from
injection-molded plastic that won't melt. The handle, which allows a user to
handle the iron without being burned, also holds the controls for the thermostat
and steam release.
 Power: Most irons have a power cord to access electricity needed to heat the
water to steam and to heat the sole plate to the desired temperature.
Modern irons for home use can have the following features:
 A design that allows the iron to be set down, usually standing on its end, without the hot
soleplate touching anything that could be damaged;
 A thermostat ensuring maintenance of a constant temperature;
 A temperature control dial allowing the user to select the operating temperatures (usually
marked with types of cloth rather than temperatures: "silk", "wool", "cotton", "linen etc.);
 An electrical cord with heat-resistant silicone rubber insulation;
 Injection of steam through the fabric during the ironing process;
 A water reservoir inside the iron used for steam generation;
 An indicator showing the amount of water left in the reservoir,
 Constant steam: constantly sends steam through the hot part of the iron into the
clothes;
 Steam burst: sends a burst of steam through the clothes when the user presses a
button;
 (advanced feature) Dial controlling the amount of steam to emit as a constant
stream;
 (advanced feature) Anti-drip system;
 Cord control: the point at which the cord attaches to the iron has a spring to hold the cord
out of the way while ironing and likewise when setting down the iron (prevents fires, is more
convenient, etc.);
 A retractable cord for easy storage;
 (advanced feature) non-stick coating along the sole plate to help the iron glide across the
fabric

 (advanced feature) Anti-burn control: if the iron is left flat (possibly touching clothes) for too
long, the iron shuts off to prevent scorching and fires;
 (advanced feature) Energy saving control: if the iron is left undisturbed for several (10 or 15)
minutes, the iron shuts off to save energy and prevent fires.
 Cordless irons: the iron is placed on a stand for a short period to warm up, using thermal
mass to stay hot for a short period. These are useful for light loads only. Battery power is not
viable for irons as they require more power than practical batteries can provide.
 (advanced feature) 3-way automatic shut-off(advanced feature) self-cleaning
problems Things to Check
Iron won’t heat  Is the iron plugged in and the outlet working? Check the outlet
by plugging in a lamp.
 Is Temperature Control Dial turned to a fabric setting?
 If auto shutoff model, is the Reset Button/Light Illuminated? If
not, push to reset
Water is leaking  Do not overfill the water tank.
out of the iron  If steam ironing, is Adjustable Steam Knob in a steam
 position that matches Temperature Control Dial steam
Range? Did the iron have enough time to preheat?
 If dry ironing, make sure the Adjustable Steam Knob is in the
dry iron position
Iron won’t steam  Check the water level.
 Is the Adjustable Steam Knob in the STEAM position?
 Has the iron had enough time to preheat?
Iron leaves spots  ALWAYS empty the water tank of the iron after
on clothing. Using. Water left in the tank may discolor clothing
and soleplate
Wrinkles not • Check Temperature Control Dial is set to Correct fabric.
removed
Iron too hot • Check Temperature Control Dial and set to lower
Setting. Let iron cool down 5 minutes before Continuing.
Common problems and trouble shooting

Table 2.3 trouble shooting of Flat iron/clothe iron

2.2. Pre-testing procedure
Pre testing is the process of testing before the post testing is done to identify the defect /faulty
parts of the electronically controlled domestic equipment.
Why Test?
There are four main reason why you should safety test your products prior to shipment
1. Safety Ensure that the product is not going to pose a hazard to the end user.
2. Quality Detect workmanship defects and prevent faulty components from being installed.
3. Cost Control Identify production problems before a product is shipped, preventing costly recalls.
Prevent product liability suits because the responsibility of performing electrical

4. Liability
safety tests ultimately rests on the manufacturer
Table 2.4 safety test
General pre testing procedures.
1. Visual inspection of the unit with power off

2. Interview of customer re history of unit
3. Be sure you understand how the domestic appliance (washing machine, micro-oven,
refrigerator etc.) Operates. If possible, read the operation’s manual first for its function and
additional features.
4. Operate the appliance according to manual to confirm defects
5. Determine what the problem really is.
6. Perform preliminary inspection to locate where the problem has originated.
7. Perform closer inspection into the suspected parts or components.
8. Use appropriate instrument in initial testing of the appliance.
9. Plan your approach to repair the problem.

2.3. System Defect/Fault Symptoms
A fault is defined as a disturbance in an electrical system of such magnitude as to
cause a malfunction of that system. It must be remembered, of course, that such
disturbance may be the secondary effects of mechanical damage or equipment
failure. Actual electrical faults, or should one say faults that are caused by
‘electricity’, are rare and are confined in the main too bad design and/or installation
or deterioration and ageing.
Troubleshoot and Fault localizing
Trouble shooting means finding the problem that is occur in the equipment. Before you begin to
troubleshoot any piece of equipment, you must be familiar with safety rules and procedures for
working on electrical equipment. These rules and procedures govern the methods you can use to
troubleshoot electrical equipment (testing procedures.) and must be followed while
troubleshooting.
Next, you need to gather information regarding the equipment and the problem. Be sure you
understand how the equipment is designed to operate. It is much easier to analyze faulty
operation when you know how it should operate. Operation or equipment manuals and drawings
are great sources of information and are helpful to have available. If there are equipment history
records, you should review them to see if there are any recurring problems. During trouble
shooting schematic diagram is important to see components of the equipment and to find the
fault easily and to reduce the time required to find the fault in different components of the
equipment.
Functional block diagram is simple than schematic diagram but for maintenance it is better to use
schematic diagram. That is, functional block diagram is simply used to explain how the
equipment operates or the operation of the circuit. So to locate different parts of the equipment
schematic diagram is preferable.

When trouble shooting is carry out we should have service data that gives the value of each
component, the block diagram and the output of each block. Therefore, it is important to detect
the fault easily.
Service data includes theory of operation, schematic diagram, functional block diagram, spire
part lists, troubleshooting procedures and alignment procedures.
The following are some common problems that can occur when using the Lakeland Gravity
Filter Coffee Maker. Please review the problems, their possible cause and any corrective action
that should be taken.
A. Care and cleaning

• Switch off and unplug the coffee maker from the socket before cleaning and when not
in use. Always allow the coffee maker to cool down completely before cleaning.
• Before the first use and after every use, clean each part thoroughly.
• Check all parts before reassembly.
• Never immerse the coffee maker in water or any other liquid.
• To clean the outer parts of the coffee maker, wipe with a clean damp cloth and dry
before storing. Do not immerse in water.
• Wash the carafe, filter basket, permanent filter, water tank lid and measuring spoon in
hot soapy water, rinse and dry thoroughly. These parts are also dishwasher safe.
• Always remove the used coffee filter from the appliance straight away after brewing.
• Store the coffee maker with the power cable loosely coiled. Never wrap it tightly
around the base unit. Use the cord storage to tidy excess cord.
• Do not use steel wool, or abrasive cleaners or materials.
• If the coffee maker is not going to be used for a period of time, empty the water tank
completely, by turning it upside down.
A. Visual inspection: - is important to localize the faulty component during trouble

shooting. Fault localizing means determining the functional unit or the electronic
equipment responsible for the indicated fault. In the initial inspection of any equipment,
first open the equipment to look at it. There are several things that can observe by using
our sense of organs. Such as broken parts, burned resistors, open wires and poor

connections, there can be smoke or smell, damaged or worn out parts. Many troubles can
be located with initial inspection using our senses. The final solution involves application
of our knowledge of electronic circuit operation and understanding of proper usage of the
test equipment. In this step by using test instruments we can check the continuity (open
circuit), short circuit, ground etc and also input output tests on the proper units is
performed in order to locate the one that was actually at fault.
Testing is an experiment in which the system is exercised and its resulting response is analyzed
to check its behavior. If incorrect behavior is detected, the system is diagnosed and locates the
cause of the misbehavior. Diagnosis requires the knowledge of the internal structure of the
system under test.
The task of detecting and diagnosing fault on appliances lies on technicians. Successful fault
finding calls for an additional skill set, including the ability to:
 devise a plan;
 think logically;
 select and use a range of test equipment;
 make a detailed record of the process.
B. Steps to Fault Finding

Step 1 - Prepare
 Are there any safety issues?
 What test equipment do you intend to use?
 Document your findings!
Step 2 - Observe
 Are there signs of damage - overheated components, melted insulation, frayed
wire, bad solder joints?
 Can you smell burning or overheating?
 Take voltage measurements from a working circuit.
 Take voltage measurements from the faulty circuit to compare.

Step 3 - Identify the problem subsystem
 Which subsystems are operating correctly?
 Where does the problem seem to lie?
Step 4 - Suggest possible causes
 Check likely components:
 Switches, fuses and bulbs tend to wear out or burn out.
 Check possible components:
 Motors, relays, inductors - components with coils - may overheat.
 Check connections:
 Look for faulty connections or loose contacts which may offer high resistance.
 Look for stray connections that can short-circuit.
 Look for breaks that create open-circuit conditions.
Step 5 - Test and repair
 Be safe! Remember -
 capacitors can store electrical charge and give electric shocks;
 Inductors can store energy in a magnetic field and give electric shocks.
 Take measurements around the circuit, but mentally predict what they should be.
 In this way, home in on the problem component(s), and replace it(them),
observing all safety procedures.
 Next, re-test the system to ensure that no other faults exist.

2.3.1. Common faults and their symptoms:
Short circuit:
• zero volts between positive and 0V power rails everywhere;
• power supply output voltage restored when the circuit is removed from the supply;
• excessive current drawn from power supply;
• the fuse protecting the circuit may ‘blow’;
• zero ohms between power rails, (with circuit removed from power supply.)
open circuit:
• zero volts between positive and 0V power rails at one end of the circuit, but not the other;
• part of the circuit may function while another part does not;
• reduced or zero current drawn from power supply.
• reverse connection:
• can occur in ‘polarised’ components - ones which only work when connected the ‘right’
way round, e.g. diodes, LEDs, transistors and some capacitors;
• can be the result of the power supply or battery being connected to the circuit the ‘wrong’
way round;
• produces an unusual voltage drop across the component.
• incorrect value or faulty component:
• an incorrect value can be identified by examining the component against that specified in
the circuit diagram;
• a faulty component may show signs of overheating or mechanical damage;
• both produce an unusual voltage drop across the component.
• incorrect component:
• can be identified by examining the component against that specified in the circuit
diagram;
• produces an unusual voltage drop across the component.
2.3.2. Importance of Testing
In Today ‘s Electronics world, more time is required for testing rather than design and
fabrication. When the circuit/device is developed, it is necessary to determine the functional and
timing specifications of the circuit/device. When the multiple copies of a circuit are

manufactured, it is essential to test each copy to verify whether the manufacturing process has
introduced any flaws. In order to meet the requirements of the consumer, it is essential to test the
circuit effectively, before it is released into the market.
Good Testing leads to:
 Better quality products
 Good brand value for company
 Total Customer satisfaction improves yield in manufacturing
A. Testing Principle
During testing, a set oftest stimulus are applied to the inputs of the Circuit/Device under test
(CUT/DUT) and the output responses are analyzed. Circuits that produce the correct output
responses for all input stimuli are considered as fault-free and the circuits that fail to produce a
correct response are assumed to be faulty.
2.3.3. Types of Testing
Manual testing and Automated Testing:

Devices can be tested in two ways, manually and automatically. Testing Devices with human
intervention is referred as Manual test. Testing devices with the help of programs or tools with
minimal human intervention is referred as Automation test. Before Automation testing of any
device, one must know how to test the particular device manually.
To identify system defects and fault symptoms follow the following basic steps
Observe systematic pre-testing procedures in accordance with manufacturer’s instructions
Check and isolate circuits using specified testing procedures
Document results of diagnosis and testing accurately and completely within the specified
timeframe Explain identified defects and faults based on the result of diagnosis and
testing Provide data/information regarding the status and serviceability of the unit as per
procedure

Electronically controlled domestic equipment defect/fault identification Checklist (e.g.
Refrigerator, washing machine, flat iron ………….)
Part of equipment condition
good defective
Power cord
Power switch
.
.
.
.
 customer’s Signature______________________ Date Repaired: ______________
technician’s Signature______________________ Date Checked: ______________
2.4. Troubleshooting procedures
Troubleshooting is a form of problem solving, often applied to repair failed products or

processes. It is a logical, systematic search for the source of a problem so that it can be solved,
and so the product or process can be made operational again. Troubleshooting is needed to
develop and maintain complex systems where the symptoms of a problem can have many
possible causes.
- Troubleshooting is used in many fields such as engineering, system
administration, electronics, automotive repair, and diagnostic medicine. Troubleshooting requires
identification of the malfunction(s) or symptoms within a system. Then, experience is commonly
used to generate possible causes of the symptoms. Determining which cause is most likely is
often a process of elimination - eliminating potential causes of a problem.
Finally, troubleshooting requires confirmation that the solution restores the product or process to
its working state

Basic steps of Troubleshooting
Step1 analysis
Step2 problem identification/replication
Step3 action plan
Step4 implementation
Step5 testing
Step 6 documentation
Step7 follow up
Figure 2.14
Figure 2.15 steps of Troubleshooting

2.5. checking and isolating Circuits
how to test them. Once you've gotten over this hurdle, you have to write test procedures
specifying exactly how the board will be tested. Remember, you want to test all the circuits;
otherwise, you can't be sure the board will work properly under all normal operation conditions.
Once you've written the test procedures, you have to assemble all the necessary test equipment:
oscilloscopes, voltage sources, current sources, meters. and so on.
2.5.1. Manual testing

Now, connect all this equipment to the appropriate points on the pc board. Some of those points
may be hard to reach. If you have many boards to test, vou may want to build a fixture to
simplify connecting the test leads.
Finally, turn on the equipment, apply known inputs to the circuit, check the outputs and
determine if the circuit is operating properly. And, oh yes, if the circuit is not operating
properly, find the defective part and replace it.
The term automatic test equipment (ATE) applies to many forms of programmable, computer-
controlled test instruments and systems. This equipment is used in many stages of the
manufacturing process, including:
 Component manufacturing
 Quality assurance
 Income inspection
 PC board testing
 System testing
 Field service
2.5.2. What Es an in-circuit sestet?

It's a tester that tests each component on a pc board, one at a time. And it does this while the
component is "in-circuit," that is, while it's connected to other components on the board. A
divide-and-conquer approach is taken. First, the tester checks the loaded pc board for unwanted
shorts and opens. Then, it isolates and tests each separate component on the board, one at a time.

The tester performs all the manual procedures that were described:
 Writes test procedures
 Connects the test equipment to the board
 Turns the equipment on and sets it up
 Applies known input signals and checks outputs
 Determines if the circuit is OK
 Locates defective components when the circuit is not OK and last, but not least,
 Repeats this for all the circuitry on the board
In-circuit testing’s
Test the individual components on fully assembled pc board: It must have access to all the
circuit nodes on the board. Obviously, to test each component individually, the raster must be
able to connect test instruments to each pin of each component. Also, it must be able to isolate
each component-under-tc5t from surrounding components. Since components. Inter connected
on the board, some special isolation techniques are needed to prevent the component-under-test
from being affected by other components.
Analog testing
To perform analog testing. the tester uses the following instruments:
 DC Current Source
 DC Voltage Source
 DC Voltmeter
 DC Ammeter (Current filter)
 AC Impedance measurement module
Now, the question is, how can the taster connect any one of these instruments to any one of
hundreds of' circuit node. on the hoard. Isolating and testing analog components Suppose you
wanted to test an analog component, such as a Resistor. that is not connected in a circuit. You
could apply a known voltage across that resistor, measure the
Resulting current, and calculate resistance by using Ohm's Law:

R=V/I.
For example, if the applied voltage were 1.0 V and the measured current were 1.0 mA, the
calculated resistor value would be
Test program
Example of electronic circuit testing

Method of identifying non-functional tools and equipment
1. Visual inspection. It refers to the visual observation of an expert on the appearance of
the tools and equipment.
2. Functionality. Vibration or extra noise from the operation means problems on parts and
accessories started to develop.
3. Performance. When there is something wrong with the performance of either hand tools
or equipment they need an immediate repair or maintenance.
4. Power supply (for electrically operated only). Failure to meet the required power supply,
malfunction will occurs in the part of hand tools or equipment.
5. Person’s involved. It refers to the technical person who has the knowledge and skills about
the technology.
2.6. Documenting Results of diagnosis and testing

Documentation
The organizational Unit is to keep testing and inspection records which are to be stored on a
shared system drive.
Table 1 diagnosis and testing

 Complete, accurate, and current documentation is essential to an effective maintenance
program. Whether performing preventive, predictive, or reliability centered maintenance,
keeping track of equipment condition and maintenance—performed and planned—is
critical.

 Maintenance recommendations contained in this volume should be used as the basis for
establishing or refining a maintenance schedule. Recommendations can be converted into
Job Plans or Work Orders in MAXIMO or another maintenance management system.
Once these job plans and work orders are established, implementation of well-executed
maintenance is possible.
 The maintenance recordkeeping system must be kept current so that a complete
maintenance history of each piece of equipment is available at all times. This is important
for planning and conducting an ongoing maintenance program and provides
documentation needed for the Power O&M Reviews.
 Regular maintenance and emergency maintenance must be well documented as should
special work done during overhauls and replacement. The availability of up-to-date
drawings to management and maintenance staff is extremely important. Accurate
drawings are very important to ongoing maintenance, testing, and new construction; but
they are essential during emergencies for troubleshooting. In addition, accurate drawings
are important to the continued safety of the staff working on the equipment.
2.7. Customers service

After all the information has been gathered, the service advisor returns with the customer to the
advisor’s desk in the service department. At this point, the advisor takes all of the information
gathered to generate a repair order, which is the beginning of the record stored in the computer
system. The repair order is the document used to authorize the work being requested by the
customer and any additional recommendations they have approved. After this has been
generated, the next step is to give an accurate cost estimate to the customer and let them review
the repair order.
After the initial part of the service agreement has been completed, the service advisor is
then responsible for ensuring that the customer is aware of a timeline for the repair and
forgathering appropriate contact information. Once the repair has been authorized the
communication and relationship building continues throughout the service process between the
advisor and the customer. For example, if the advisor were to tell the customer that the repair
will be done right away, but the car is in the shop for the entire day, the advisor would not be
providing an accurate representation of the repair. Each instance is different: Some customers

may be in for only a routine oil change and may opt to wait for the vehicle to be repaired. That is
why it is crucial to provide accurate repair estimates with timelines, So that there are no
questions or flags raised that could affect how the customer trusts the Dealership.
Reporting a Diagnosis
Customers bring their machines into the service department for a variety of reasons: one of the
main reasons customers return to the dealership is that they want factory-certified technicians to
diagnose their machines issues. Customers expect the dealership of their equipment to be the
expert, and they understand that such expertise might come with a premium cost. Dealerships
have this level of legitimacy typically as an assumption, something that local shops have to build
up over time with their customer base. The service advisor is the main point of contact for the
repair estimate. After the technician performs the multipoint inspection and diagnoses the
vehicle, it is their job to gather the quote for necessary parts and hours to complete the job. They
pass this information onto the advisor to call the customer and report their findings. This quote
may also include other recommendations found by the technician during their diagnostic.
 Advising is used when an employee’s problems impact performance and is intended to
mitigate any further action, including formal disciplinary action. The employee should solve
the problem and your role is to be positive, supportive, and encouraging in that process.
(Refer to the Toolkit documents, “Counseling Your Employees, The 2-Minute Challenge”
and “Counseling Your Employees, The Role of a Good Supervisor”.)
Advising customers depend on: -
How to safe from accidents
How to use equipment
How to safe the equipment rom adults
When/how to clean the equipment

Self-check-2
Test-I: Choose
Instruction: For the Following Questions You Are Given Four Alternatives Then Choose the
Correct Answer and circle
1, To be trouble shooter one must be a knowledge of A, tools needed B, basic
electronic/electrical component C, basic electronic/electrical ckt analysis D, all of the above
2, Advising customers depend on (3 pt )
A, how to safe from accidents B, how to use equipment’s C, how to safe the equipment’s
roomfuls D, When/how to clean the equipment’s E. all
3. Make an initial inspection/ testing of the appliance. (3 pt each)
A. Physical appearance
B, Operating controls
C. Power cord . D. all
Test-II: Say true or false.

1, Troubleshooting is used in many fields such as engineering, system
administration, electronics, automotive repair, and diagnostic medicine.
2, write basic steps of Troubleshooting.
3, Hot Test is the test performing with power source.
4, which one is the method to identifying non-functional tools and equipment.
Test III: short Answer writing

1. write Types of tasting?
2. Write down Basic steps of Troubleshooting?
3. Write down analog testing instruments?

Operation sheet-2
Operation Title: Reassemble units Techniques

Purpose: To Reassemble Units Techniques
Instruction: Using the figure below and given equipments to Reassemble Units Techniques.
You have given 30Minut for the task and you are expected to write the answer on the given line.
 Multimeter
 Utility knife/stripper
 Wrenches (assorted)
 Allen wrench/key
 Screws (assorted)
 Pliers (assorted)
Procedures:
1. Visual inspection of the unit with power off
2. Interview of customer re history of unit
3. Be sure you understand how the domestic appliance (washing machine, micro-oven,
refrigerator etc.) Operates. If possible, read the operation’s manual first for its function and
additional features.
4. Operate the appliance according to manual to confirm defects
5. Determine what the problem really is.
6. Perform preliminary inspection to locate where the problem has originated.
7. Perform closer inspection into the suspected parts or components.
8. Use appropriate instrument in initial testing of the appliance.
9. Plan your approach to repair the problem.
 Quality Criteria: the given Single phase power supply is troubleshooting properly.
 Precautions: use the given multimter without damage.

LAP Test-2 Practical Demonstration
Name: __________________________ Date: ____________
Instruction I: Given necessary templates, tools and materials you are required to perform the
Task 1. Check electronically-controlled domestic appliances

Task 2. Pre-test procedure
Task 3. Identify System defect/fault symptoms
Task 4. Use testing instruments in accordance with user manuals and safety procedures
Task 5. Implement Proper troubleshooting procedures
Task 6. Test circuits
Task 7. Explain Identify defects and faults
Task 8. Check Control settings/adjustments
Task 9. Document Results of diagnosis and testing
Task 10. Advise/inform customers regarding the status and serviceability

Unit Three: Unit maintenance/repair
 Utilization of Personal Protective Equipment
 Electrostatic discharge (ESD) protection procedure
 defective parts/components
 Unit cleaning
 Using Personal protective equipments
 Electro-static discharge (ESD) protection procedure
 Replacing soldering & mounting defective parts/components
 Performing cleaning of unit

3.1. Personal protective equipment
Occupational Safety and Health (OHS) is a cross-disciplinary area concerned with protecting
the safety, health and welfare of people engaged in work or employment. The goal of all
occupational safety and health programs is to foster a safe work environment. As a secondary
effect, it may also protect co-workers, family members, employers, customers, suppliers, nearby
communities, and other members of the public who are impacted by the workplace environment.
It may involve interactions among many subject areas, including occupational medicine,
occupational (or industrial) hygiene, public health, safety engineering / industrial engineering,
chemistry, health physics.
Risks include acute and chronic health effects, for example, irritation or cancer, and physical
effects such as fires or explosions. The hazards are physical and health hazards.
A hazard is something that can cause harm, eg electricity, chemicals, working up a ladder,
noise, a keyboard, a bully at work, stress.
Risk is the chance or probability that a person will be harmed or experience an adverse health
effect once to a hazard. It may also apply to situations with property or equipment loss. A risk is
the chance, high or low, that any hazard will actually cause somebody harm.
Figure 3.1. hazards

For example, working alone away from your office can be a hazard. The risk of personal danger
may be high. Electrical repair is a hazard. If someone accidentally turned on the power the
worker’s life will be in a 'high-risk' category.
Risk assessment
A. Risk assessment is the process where you:
1. identify hazards
2. analyze or evaluate the risk associated with that hazard
3. determine appropriate ways to eliminate or control the hazard
B. Factors that influence the degree of risk include:
1. how much a person is exposed to a hazardous thing or condition
2. how the person is exposed (e.g., breathing in a vapor, skin contact), and how
severe are the effects under the conditions of exposure
3.2. Electro-static discharge (ESD) protection

What is ESD? Electrostatic Discharge is a high voltage event from the release of electrical
energy caused by static electricity or electrostatic induction.
ESD can cause permanent damage to electronics and integrated circuits.
ESD Principle Protect the IC by suppressing incoming transient voltage to an

acceptable level (Output of Vc: Clamping voltage).
Figure 3.2. Electrostatic Discharge

3.2.1. Types of ESD
1) Sparks – A spark is triggered when the electric field strength exceeds approximately
4-30kV/cm. This may cause a very rapid increase of free electrons and ions in the air,
temporarily causing the air to abruptly become an electrical conductor. eg, lightning.
2) Corona discharge – A corona discharge occurs between a highly curved electrode

(eg, tip of pen) and an electrode of low curvature (eg flat plate)
3) Brush discharge – A brush discharge occurs between an electrode with a curvature

between 5mm and 50mm and a voltage of about 500 kV/m. The resulting discharge paths
have the shape of a brush.
3.2.2. ESD Simulations
There are three models for assessing the survivability/susceptibility of electronic devices to ESD:
1)Human Body Model, HBM
2)Machine Model, MM
3)Charged Device Model, CDM
1. Human Body Model - HBM
• Simulates ESD from human contact.
• A person accumulates static electricity from walking or moving and discharges the static
through the IC. The leads become the conductive path to a grounded surface due to
contact.

Figure 3.3. Human Body Model
• HBM (Human Body Model) test circuit simulates ESD from human contact
and consists of 100pF and 1.5KΩ to simulate the equivalent capacitance and
resistance of a human body.
• The capacitor is charged to a predetermined high voltage from an external source, and
then suddenly discharged through the resistor into an electrical terminal of the device
under test (DUT).
Fig3.4 Human Body Model (HBM) test circuit
2. Machine Model - MM
This simulates the discharge of static electricity accumulated from machines and equipment (i.e.
moving mechanical arms, test probes, etc.)
The test circuit consists of charging a 200pF capacitor to a predetermined high voltage from an
external source, and then suddenly discharging the DUT through an electrical terminal.
Fig3.5 Machine Model (MM) test circuit

3. Charged Device Model – CDM
• The CDM test simulates how the device acts when the device itself has an
electrostatic charge and the effects of the discharge when it comes in contact with
a metallic surface. This type of discharge is the most common type of ESD in
electronic devices and is the main cause of ESD damage during the manufacturing
process.
• CDM discharge depends mainly on parasitic parameters of the discharge and is strongly
dependent on the size and type of component package.
CDM Scenario：
When the IC slides from the packaging tube, friction causes static to form on the
device. The IC discharges as the terminals contact a grounded surface (i.e. metal
table), or when the part is picked up with metallic tweezers
Fig3.6 CDM Scenario
3.2.3. Electrostatic discharge testing (CDM)
Simulates ESD in a charged device at 150pF and 330Ω. The capacitor is charged to a specific
high voltage from an external source, and then suddenly discharged through the resistor into an
electrical terminal of the device under test (DUT).

IEC – International Electro Technical Commission: standards & specifications
61000: Electromagnetic Compatibility (EMC)

Parts 1, 2, & 3: General, Environment, Limits
Part 4: Testing & Measurement Techniques
4-2: Electrostatic Discharge Immunity
4-3: Radiated, RF, Electromagnetic Field Immunity
4-4: Electrical Fast Transients/Burst Immunity
4-5: Surge Immunity
3.2.4. ESD Protection Procedure

1. Anti-static kit can be purchased from a computer or electronics store. The main component is
an ESD wrist strap with a wire several feet long having an alligator clip at the other end.
2. Before troubleshooting any domestic appliance, wear an ESD wrist strap and wear it as you go
under the covers, handle ICs, and circuit boards.
3. Put the adjustable strap around your wrist. If you are wearing an ESD wrist strap connected to
frame or ground, it drains static charges of your body, thus, it prevents damaging ESD sensitive
devices.
4. Attach the clip at the end of the wire to an electrical ground connection or metal framework of
the washing machine.
5. If you work on a washing machine without a conductive wrist strap, touch an electrical
appliance such as a lamp or the screw in a wall outlet cover plate before touching the PCB. An
electrostatic discharge of just a few hundred volts is too small to feel in most cases but can be
usually deadly to ESD sensitive devices. Also avoid wearing clothes that easily produce a static
charge, such as knits and wools and limit your movements as much as possible, especially on
carpets while working on electronic circuits of a washing machine.

3.3. Replacing Defective parts/components
Operation of an electric flat iron, parts and functions

The domestic Electric Flat Iron was the first of the household heating devices to receive
universal recognition. From the power source at home, electricity flows through a flat cord
passes through a thermal fuse and a temperature control going to the heating element. Heating
element is insulated by a mica insulator from the body and it heats up the sole plate for the
purpose of removing wrinkles from fabric. With the heat and the weight of the ironing plate, the
fibers are stretched and the fabric maintains its new shape when cool. Some materials such as
cotton require the use of water to loosen the intermolecular bonds. Many materials developed in
the twentieth century are advertised as needing
little or no ironing. Modern irons for home use can have the following feature:
1. a method of setting the iron down 2.a thermostat to ensure maintenance of constant
temperature
3. a temperature control dial (usually marked with types of cloth) 4. an electrical cord with heat
resistant Teflon insulation 5. a steam features
6. a cord control/ anti-burn control/ energy-saving control/ cordless iron
figure3.7 Electric Flat Iron

Example of Common Electric Flat Iron

Figure 3.8 Electric Flat Iron
Basic Parts of Flat Iron

1. AC line cord is used to connect the unit to power source.
Figure 3.9 AC line cord

2. Selector Switch is a type of switch used to select the amount of heat required in ironing
different types of fabrics. It can be a rotary or slide type.
Figure 3.10 Selector Switch

3. Thermal Fuse is a safety protective device used to cut-off the circuit when the temperature
rises at above normal as designed for the unit. It also protects the unit from damage when
overheating and
short circuit occurs.
Figure 3.11
4. Heating Element is a form of nichrome wire that assembles properly inside the high
temperature metallic tube in flat iron to provide heat.
Figure 3.12. Heating Element

5. Soleplate is a base metal that serves as fabric pressing part made of metal where the heating
element is placed

Figure 3.13 Soleplate
6. Handle is the part of a flat iron by which it is carried or controlled
Figure 3.14 Handle

7. Body/Case is used to protect the internal parts of the flat iron and serve as shield for the heat
and protection of the hand of the user.
figure 3.15 Body/Case

8. Neon/Pilot Lamp is used to indicate that electricity is flowing along the heating element.
figure 3.16 Neon/Pilot Lamp

9. Thermostat Assembly is used to regulate the temperature.
Figure3.17 Thermostat

10. Electronic Control is the added feature of modern electric flat iron which can act as timer or
automatic power cut-off switch for additional protection.
figure3.18 Electronic Control

Note: To avoid a circuit from overload, do not operate another high wattage appliance on the
same circuit. If an extension cord is absolutely necessary, a 16A cord should be used with a
220V iron. Cords rated for less amperage may overheat. Care should be taken to arrange the cord
so that it cannot be pulled or rippled over.
Sample Schematic Diagram
Figure3.19 Flat Iron Schematic

Parts of Thermostat Assembly
Figure3.20 Parts of Thermostat

Heating as one of the effects of electricity
electricity is also converted into another usable power like heat. When an electric current flow
through a wire some loss occurs and this loss is almost inevitable, more the resistance of wire,
more the loss. This loss is due to the electrical resistance of wire is mainly responsible for the
heating effect of electric current.
The more electrical resistance of the wire, the more generated heat. The fixed atoms of the wire
resist the flow electrons and as a result, there are collisions and as the kinetic energy converts
into heat energy we see that the wire is getting hot.
Electric heating has several advantages: it can be precisely controlled to allow a uniformity of
temperature within very narrow limits; it is cleaner than other methods of heating because it does
not involve any combustion; it is considered safe because it is protected from overloading by
automatic breakers; it is quick to use and to adjust; and it is relatively quiet.
For these reasons, electric heat is widely chosen for industrial, commercial, and residential use.
Resistance heaters produce heat by passing an electric current through a resistance: a coil, wire,
or other obstacle which impedes current and causes it to give off heat. Heaters of this kind have
an inherent efficiency of 100% in converting electric energy into heat. Devices such as electric
ranges, ovens, hot-water heaters, sterilizers, stills, baths, furnaces, and space heaters are part of
the long list of resistance heating equipment.
Procedure in Pre-Testing and Troubleshooting an Electric Flat Iron
1. Determine the specific problem by asking the symptom.

a. Ask the owner/operator of the electric fan of what is the symptom of the unit.
b. Request for the details of the symptom (how does the symptom happen) and how long it has
been observed).
2. Operate the device. Make sure that you know how to operate an electric flat iron. If not,
review the operating manual as well as the service manual (if available) of the unit prior to its
testing and operation
a. If you have worked on the same unit before, test out to see if it operates in the same way.
b. Determine the last time it has been modified/repaired.

c. You must recognize the symptom/ complain of the owner to the unit.
3. Perform visual inspection of the unit.
a. Prepare the tools needed and remove the cover ready for inspection.
b. Apply careful physical inspection of the parts/components. (Look for burned and broken
components; Inspect for loose connections or broken wires)
4. If all looks fine, test the unit for resistance checks.
a. Get the multitester and set it at range Rx1. Connect the test probes to each of the plug
terminals, the reading must be infinite having the temperature control at zero position.
b. Then, adjust slowly the temperature control, decrease in resistance should be observed. If this
happen, the unit might be in good condition. For safety, place one probe across to the plug
terminals and the other probe to the body. There should be very high (infinite) resistance. If
there’s something different, refer to troubleshooting guide on this lesson.
5. Record your findings for future reference.
How to use an electric flat iron
1. Adjust the temperature selector to a minimum position before plugging cord into electrical
outlet.
2. Pre-heat the unit at least 2 minutes before using.
3. To improve dry ironing results, sprinkle the garments with water evenly at least one hour
before ironing.
4. Unplug iron by gripping plug and pulling it from the outlet. Never pull the cord.
Diagnosing and Troubleshooting Procedure/ Guide:

Table 3.1 Diagnosing and Troubleshooting
TROUBLESHOOTING, MAINTENANCE AND CLEANING TIPS

Troubleshooting
6. Conduct a quick diagnosis of the trouble symptom and repair the defective set in the shortest
possible time. Do not troubleshoot an electric flat iron unless you have determined the fault.
7. Secure a circuit diagram.
8. If the iron doesn’t heat, make sure power is on to the outlet, check the electrical cord, and
check the thermostat.
9. Always suspect a faulty contact on mechanical switch circuit rather than defective
electronic/electrical parts.
5. If the iron produces too much or too little heat, test the electrical cord for loose wiring and
connection. Also test and, if needed, adjust calibration of the thermostat.
6. Use Personal Protective Equipment. Maintenance and Cleaning
1. Turn-off and unplug the electric flat iron and make sure it’s cool before cleaning.

2. Check the owner’s manual for your iron to learn the specified manufacturer’s suggestions for
cleaning.
3. You may use a sponge and commercial soleplate cleaner or baking soda and water to remove
dirt buildup on the soleplate. Rinse well with water and dry. Don’t submerge an electric flat iron
in water or cleaning liquid. If needed, use very fine emery cloth or sand paper to remove
scratches and burns on the soleplate. Don’t use harsh abrasives.
REASSEMBLING AND TESTING AN ELECTRIC FLAT IRON

Reassembling Procedure:
1. After replacing the defective part of the appliance, prepare the parts for reassembling. Make
sure that there are no missing parts or component and as well as the screws.
2. Review the operating and service manual if available.
3. Fix all the disassembled parts in the housing/compartment, considering the fittings, lock etc.
4. Wires should be in their proper places and loose parts should be tightened to avoid damaged
due to misalignment.
5. All sides of the housing should fit. See to it that Selector Switch is moving appropriately and
the rest of the movable parts.
6. Clean the unit before doing the testing procedure.
Testing Procedure:
1. Set the ohmmeter to Rx1.Test the AC plug to determine the continuity of the power line to the
heating element. Reading must be around 14 ohms.
2. Energize the unit to check its functionality. Move the Selector Switch slowly. Within a minute
or two, the unit should operate normally. If not, review the documentation and troubleshoot
again.
3.4. Cleaning of unit

Cleaning is an essential process within electronics manufacture and has been used for many
years to remove potentially harmful contaminants during PCB manufacture. Such contaminants
include flux, solder and adhesive residues, and other more general contaminants such as dust and
debris present from other manufacturing processes.

Cleaning PCBs has been a vast topic for many years, particularly so since the ban of CFCs and
HCFCs. These products offered solvency power, low surface tension properties to dissolve,
remove and dry within minutes any parts of any de-sign. The electronic industry has grown so
rapidly since the 80s, that today, nearly 50% of any individual’s belongings are composed of
electronics: e.g.: Mobile phones, remote controls, TVs, radios, cars, IPods, computers, HiFi, hard
discs, memory sticks, cameras, videos, refrigerators, dish and laundry washers, cars, planes,
satellites, implants, etc…
Since the 90s, the electronic evolution has been exponential, and the miniaturization has
advanced proportionally. The introduction of such new small parts not only raised some design
problems, but also some practical aspects such as handling and some reliability problems. In
meantime, the suppliers of solder fluxes and pastes had to adjust new formula-tions for the new
markets, the new demands and the new regulations.
Accordingly, the electronic suppliers adapted their production to the customers’ demands with
cleanable and no clean fluxes, also called consumable devices. The non-consumable devices
such as medical implants, military tools, satellites, safety parts for cars, trains, medical
equipments and many other products, should be reliable and thus cleaned. To achieve a good
cleaning result, it is worth understanding the various parameters present and the physical laws
which are ruling this chemical operation.
Cleaning has a cost and it should be adapted to the needs while maintaining stability in time,
efficiency, quality and performance.
1) Miniaturization
Today, miniaturization is a hundred times greater than during the 80’s. This reduction in size
means reduction of solder pads and also amount of flux residues. But it also means a reduction of
space between legs and board/components. Today, size of components are down to 0, 1mm.In
addition, the components became of high capacity with resistors, diodes, quartz, selfs, BGA and
others. The reliability of these components should be always increased. This miniaturization

should not become a reason of instability and unreliability. The cleanliness should be performed
and pass the norms.
2) Contaminants
The contaminants on a circuit board are mainly composed of: organics such as natural and/or
synthetic rosins, ions, acids, solder balls, fingerprints, and particulates of PCBs. The lead-free
alloys need higher soldering temperatures than the standard Sn/Pb which are carrying significant
evolutions on the fluxes to be used. These fluxes are most of the time more active and must resist
to higher reflow profiles. They present more risks than the one formerly used , and the
temptation is high to choose production parameters allowing shining soldering pads. The ionic
cleaning of the PCBs is then more critic-cal before tropicalisation, but will also help to control
the assembling process and help to establish final assembly life-time. The ionic contamination is
a good quality indicator for the long term reliability. Please see next Figure
Figure 3.21 cleaning of the PCBs
3) Specifications set up
Every end-user has his own typical specifications which are depending on his own or his
customers. For this study, the specifications have been taken as described i. Six hundred PC Bs
for trials were produced in large quantities to triple the cleaning results (Figure 3.22). Each trial
contains 30 components. All residues must disappear, including the con-taminants under the
components. No fingerprint, particle or dust should remain, including residues of cleaning
products. The components, the rosins, the under fill and the substrate should not be damaged by

the cleaning operation. The part should be dried at the end of the washing step. The ink
markings should be resistant to the cleaning.
Figure 3.22 cleaning operation
4) Cleaning products available
The most important part of the job is to remember which chemical families are available in the
market. The cleaning products available can be classified in five different families: The
detergents, the light petroleum distillates, Formulated hydrocarbons, Brominated solvents,
glycols and fluorinated solvents.
GENERAL RECOMMENDATIONS FOR CLEANING

 Electronic devices in both clinical and non-clinical areas become contaminated with
microorganisms, which are transmitted via contaminated hands. Follow the guidance in
Table 3.2 for electronic cleaning and disinfecting devices.
 Unless there is a protective, washable cover for the electronic mobile device it should not
come into contact with the patient environment.
 Replace computer components when:
 Grossly contaminated e.g. saturated with blood or body fluids or
 Cleaning doesn’t remove visible soil, e.g., keyboards.

Table 3.2 electronic cleaning and disinfecting devices

Self-check – 3
Test-I Choose
Directions: For the Following Questions You Are Given Four Alternatives Then Choose the
1, One of the ff is not The double burner solar stove main component? (3 pt each)
A. Heater coil B. Heat controller C. Battery D. Charge controller . E. none of the above
2. The base metal part of electric flat iron that presses the fabric.
A. AC Cord C. Neon/Pilot Lamp
B. Body/Case D. Sole Plate
3. Connects the unit to power source.
A. AC Cord C. Neon/Pilot Lamp
B. Body/Case D. Sole Plate
4. It is a hand tool used in holding, gripping and cutting of wires.
A. Blade cutter B. Pliers
C. Screwdriver D. Soldering iron
5. It is a measuring instrument used to check continuity and resistance of
a circuit. A. Ammeter B. Ohmmeter C. Voltmeter D. Wattmeter
Test II: short Answer writing

Instruction: write short answer for the given question
1. How to use an electric flat iron?
2. Write down Basic Parts of Flat Iron?
3. Write down Reassembling Procedure for Flat Iron?
Test III: Say true or false
1.Testing methods and standards are set for Direct Discharge and Air Discharge.
2.Electrostatic Discharge is a high voltage event from the release of electrical energy caused by
static electricity or electrostatic induction
3. During use of a coffee maker A cut off plug inserted into a 13amp socket is a serious safety
(shock) hazard. Ensure the cut off plug is disposed of safely

Operation sheet-3
Operation Title: Completing maintain/repairing Service
Purpose: To maintain/repairing Service
Instruction: Using the figure below and given equipments maintain/repairing Service. You have
given 40 Minut for the task and you are expected to write the answer on the given line.

 Single phase power supply
 Multimeter
 Soldering iron
 Flux
 Lead
Steps in doing the task
1.Conduct a quick diagnosis of the trouble symptom and repair the defective set in the shortest
possible time. Do not troubleshoot an electric flat iron unless you have determined the fault.
2. Secure a circuit diagram.
3. If the iron doesn’t heat, make sure power is on to the outlet, check the electrical cord, and
check the thermostat.
4. Always suspect a faulty contact on mechanical switch circuit rather than defective
electronic/electrical parts.
5. If the iron produces too much or too little heat, test the electrical cord for loose wiring and
connection. Also test and, if needed, adjust calibration of the thermostat.
6. Use Personal Protective Equipment. Maintenance and Cleaning
 Quality Criteria: the given power supply is troubleshooting properly.

 Precautions: use the given multimter without damage.

LAP Test-3
Name: __________________________ Date: ____________
Task 1. Occupational Health and Safety’s

Task 2. Electro-static discharge (ESD) protection procedure
Task 3. Replacing Defective parts/components
Task 4. Soldering/mounting Repaired or replaced parts/components
Task 5. Performing Control settings/adjustments in conformity with service-manual
specifications
Task 6. Performing Repair activity within the required timeframe
Task 7. Observing Care and extreme precaution during handling the unit/product as
per procedures
Task 8. Cleaning with standard procedures
.

Unit Four: Unit repair test
 Assembly of repaired units
 Reassembled unit final testing and cleaning
 Adherence to Service completion procedures and documentation
 Waste Materials Disposal
 Reassembling repaired units
 Final testing and cleaning reassembled units
 Complying Service completion procedures and documentations
 Disposing Waste materials

4.1. Assembly of repaired units
Reassemble units: -is the process of assembling each parts of the appliance.
1. After replacing the defective part of the appliance, prepare the parts for reassembling.
4. Wires should be in their proper places and loose parts should be
5. All sides of the housing should fit accordingly.
6. Moving parts must move as it can be moved by hand and free from obstructions.
7. Tightened to avoid damaged due to misalignment.
9. perform final test.
4.2. Reassembled unit final testing and cleaning
Post-testing Procedure:
1. Test the resistance at the AC plug to determine the continuity of the power line to the AC unit. A
resistance reading must be observed as you turn the switch to ON position. This indicates that the circuit
connection is good.
2. In the case of electronically-controlled domestic equipment, there is no resistance reading as you test
the AC plug. The reason is that there is a low-voltage power supply circuit that controls the functions of
the appliance.
3. Energize the unit to check its functionality. Plug the AC cord to the power source (the switch is at OFF
position and power ON button for electronically-controlled must be OFF too). Turn the switch
accordingly and observe if the unit functions as it should be. In the case of electronically-controlled, press
button one at a time observing the behavior. This time, the unit should operate normally. If not, review the
documentation and the problem for the second time.

Testing Procedure:
1. Test the resistance at the AC plug to determine the continuity of the power line to the AC unit. A
resistance reading must be observed as you expect in normal.
2. Energize the unit to check its functionality. Press button one at a time observing the behavior. This
time, the unit should operate normally. If not, review the documentation and the problem for the second
time.
Following are definitions of three categories of test that shall apply:

4.2.1. Operational Test
• That procedure required to ascertain only that a system or unit is operable. These tests
should require no special equipment or facilities other than that installed on the aircraft
and should be comparable to the tests performed by the flight crews.
• It is not intended that the operational test of the unit shall meet the specifications and
tolerances ordinarily established for overhaul, or major maintenance periods.
4.2.2. Functional Tests
• That procedure required to ascertain that a system or unit is functioning in all aspects in
accordance with minimum acceptable system or unit design specifications. These tests
may require supplemental ground support equipment and should be more specific and
detailed than an operational test. It should contain all necessary information to perform
proficiency tests to maintain system or unit reliability at an acceptable level, without
reference to additional documents.
4.2.3. System Test
• That procedure containing all adjustment specifications and tolerances required to
maintain system and/or unit performance at maximum efficiency and design
specifications. It shall be self-contained and may duplicate other tests. It is normally used
at major maintenance periods.

4.3. Service completion procedures and documentation
Completing Service Based on manual
Record all information during maintaining/repairing electronically-controlled domestic

appliance. This recorded Service information may include but not limited to:
 job report sheets
 job order
 bill of materials
 customer index
 service flowchart
 stock and inventory record
 requisition slips (for acquisition of parts) supplier index
 Apply 5S - Sort, Systematize, Sweep, Sanitize, and Self-Discipline for service compilation.
The Organizational Unit is to keep testing and inspection records which are to be stored on a
shared system drive.
 Complete, accurate, and current documentation is essential to an effective maintenance

program. Whether performing preventive, predictive, or reliability centered maintenance,

keeping track of equipment condition and maintenance—performed and planned—is
critical.
 Maintenance recommendations contained in this volume should be used as the basis for
establishing or refining a maintenance schedule. Recommendations can be converted into
Job Plans or Work Orders in MAXIMO or another maintenance management system.
Once these job plans and work orders are established, implementation of well-executed
maintenance is possible.
 The maintenance recordkeeping system must be kept current so that a complete

maintenance history of each piece of equipment is available at all times. This is important
for planning and conducting an ongoing maintenance program and provides
documentation needed for the Power O&M Reviews (section .
 Regular maintenance and emergency maintenance must be well documented as should

special work done during overhauls and replacement. The availability of up-to-date
drawings to management and maintenance staff is extremely important. Accurate
drawings are very important to ongoing maintenance, testing, and new construction; but
they are essential during emergencies for troubleshooting. In addition, accurate drawings
are important to the continued safety of the staff working on the equipment.
4.4. Waste Materials Disposal
Electronic waste, or e-waste, refers to all items of electrical and electronic equipment (EEE) and
its parts that have been discarded by its owner as waste without the intent of re-use It includes a
wide range of products – almost any household or business item with circuitry or electrical
components with power or battery supply. the definition of e-waste is very broad. It covers six
waste categories:
1. Temperature exchange equipment, more commonly referred to as cooling and freezing
equipment. Typical equipment includes refrigerators, freezers, air conditioners, heat pumps.
2. Screens, monitors. Typical equipment includes televisions, monitors, laptops, notebooks, and
tablets.

3. Lamps. Typical equipment includes fluorescent lamps, high intensity discharge lamps, and
LED lamps.
4. Large equipment. Typical equipment includes washing machines, clothes dryers, dish-washing
machines, electric stoves, large printing machines, copying equipment, and photovoltaic panels.
5. Small equipment. Typical equipment includes vacuum cleaners, microwaves, ventilation
equipment, toasters, electric kettles, electric shavers, scales, calculators, radio sets, video
cameras, electrical and electronic toys, small electrical and electronic tools, small medical
devices, small monitoring and control instruments.
6. Small IT and telecommunication equipment. Typical equipment includes mobile phones,
Global Positioning Systems (GPS), pocket calculators, routers, personal computers, printers,
telephones.
Each product of the six e-waste categories has a deferent lifetime profile, which means that each
category has deferent waste quantities, economic values, as well as potential environmental and
health impacts, if recycled inappropriately. Consequently, the collection and logistical processes
and recycling technology differ for each category, in the same way as the consumers’ attitudes
when disposing of the electrical and electronic equipment also vary.EEE products have been
categorized into various groupings by pieces of national legislation taking into account their
original purpose, size, composition and/or weight.
1. Large household appliances, such as large cooling equipment like refrigerators, freezers, or
equipment for cookers, microwave ovens, etc.
2. Small household appliances, such as cleaning equipment like vacuum cleaners and irons.
3. Information technology (IT) and telecommunication equipment, personal computers, laptops,
printers, photocopiers, telephones, cell phones, modems, routers, tablets, data processing
management equipment, etc.
4. Consumer electronics, such as radios, televisions, video cameras, musical instruments, etc.
5. Lighting equipment, fluorescent lamps, compact fluorescent, excluding incandescent lamps for
homes.
6. Electrical and electronic tools (except fixed industrial tools of great significance) like crushing
equipment for coatings.
7. Toys or sporting and leisure equipment, video consoles, trains, electric cars, etc.
8. Medical devices (with the exception of all implanted and infected products), such as cardiology

equipment, radiotherapy, dialysis, etc.
9. Monitoring and control instruments, such as smoke detectors, thermostats, control panels, etc.
10. Vending machines for drinks, automated teller machines (ATMs), etc.
The characteristics of each of these categories will determine the best treatment process and
disposal for their respective equipment after EoL. The logistics of collection, management and
recycling of this equipment should be carried out according to its characteristics. E-waste can
come from household, professional, industrial, institutional or other uses. Its generation depends
on several factors, including the useful life of the equipment (e.g., computers, televisions, etc.),
the need for renewal of the equipment by users (e.g., mobile phones) and major technological
changes (e.g., the global system for mobile communications (GSM) to the universal mobile
telecommunications system (UMTS) mobile telephony). For example, according to Step
Initiative and the Massachusetts Institute of Technology (MIT), the average lifespan of a mobile
phone is estimated at three to five years. (GSMA, 2014) This use should be taken into account as
it highly contributes to the rapid growth of e-waste globally.
Sustainable management of e-waste
The majority of the e-waste and its components are recycled or reused by formal or informal
programmers, depending on the recycling capacities of the country where the e-waste is
generated. If e-waste is properly managed, business opportunities can be created to meet the need
for reconditioning of equipment and recovery of raw materials. Governments, non-governmental
organizations (NGOs) and the ICT sector consider e-waste management a tool and opportunity
for sustainable development. (ITU, 2014) E-waste is a complex mixture of hazardous and non-
hazardous materials that requires specialized processes of collection, transportation, segregation,
treatment and disposal. It is important to be familiar with the life cycle of EEE to understand its
potential environmental impacts. Figure 4.1 describes the life cycle of EEE and the processes it
undergoes once it becomes e-waste.

Figure 4.1 life cycle of EEE
There are some basic principles and definitions of environmental sustainability for the
management of e-waste.
Reuse: Extension of the end of life of equipment or component parts to be used for the same
purpose for which they were originally conceptualized; this may or may not include a change in
ownership of the equipment.
This process aims to promote optimal use of available resources, but social or environmental
risks associated with poor management should be taken into account.
Dismantling and segregation: This involves careful manual separation of the parts and
components of a piece of equipment in disuse. It is suggested that this activity be carried out by
authorized recycling companies that specialize in reconditioning.
Recycling and recovery: This process involves the recovery of devices, components and
material. The dismantling can be manual or semi-manual. The recovery of materials is part of the
WEEE recycling process, especially for metal recovery, which requires specialized facilities and
investment.
Refurbishment: This is any process that allows re-utilization of EEE that was previously
WEEE. It includes changes in hardware and software.
Final disposition: In the process of final disposal of waste or materials, non-recoverable

materials can be disposed of in controlled landfills (dumps) or by incinerating

The principles of reduce, reuse and recycle (3Rs) should also be taken into account for the proper
management of e-waste in order to minimize the generation of waste throughout its life cycle by
employing innovative and efficient processes and technologies. Reuse is an alternative that
should include the implementation of a proper collection and refurbishment process. Reusing
products has its limitations; it can only temporarily extend the life of the equipment.

Self-check-4
Test-I Choose
Directions: For the Following Questions You Are Given Four Alternatives Then Choose the
1, one is not the basic principles and definitions of environmental sustainability. (4 pt each)
A, Reuse B, Recycling and recovery C, Final disposition D, none of the above
2. One of the f f is not true about equipment handling? (3 pt each)
A. Store equipment in a clean dry storage area.
B. Rinse and clean spray equipment after each use.
C. Clean spreaders and check wheel-driven gears.
D. Clean carts and wheelbarrows after use.
E. None of the above
Test II: Say true or false

1. A post testing unit is the process of testing after assembling of each parts of the appliance.
2. Record all information during maintaining/repairing electronically-controlled domestic
appliance
3. A reassemble unit is each parts the process of assembling of the appliance
Test III: short Answer writing

Instruction: write short answer for the given question
1.write the six e- waste categories?
2. write the post testing procedures of a domestic equipment’s?
3. write the recorded Service information may include?

Operation sheet-4
Operation Title: Final testing and cleaning
Purpose: To testing and cleaning
Instruction: Using the figure below and given equipments testing and cleaning. You have given
30 Minut for the task and you are expected to write the answer on the given line.

 Single phase power supply
 Multimeter
 Soldering iron
 Flux
 Lead
Steps in doing the task
1. After replacing the defective part of the appliance, prepare the parts for reassembling. Make
sure that there are no missing parts or component and as well as the screws.
4. Wires should be in their proper places and loose parts should be tightened to avoid damaged
due to misalignment.
5. All sides of the housing should fit. See to it that Selector Switch is moving appropriately and
the rest of the movable parts.
Quality Criteria: the given power supply is troubleshooting properly.
Precautions: use the given multimter without damage.

LAP Test-4
Name: __________________________ Date: ____________
following tasks within hours.
Task 1. Test repaired unit

Task 2. Reassemble units Techniques.
Task 4. Final testing and cleaning.
Task4. Completing maintain/repairing Service.
Task5.Disposing Waste materials.

Reference
1. COFFEE MAKER KM 5260 ENGLISH
2. Medical Equipment Maintenance Manual Shower pan construction,
3. K to 12 Basic Education Curriculum Technology and Livelihood Education Learning
Module
4. ELECTRICAL INSTALLATION MAINTENANCE 130 K to 12 – Technology and Livelihood
Education
5. Managing electrical risks in the workplace
6. CENTRAL PUBLIC WORKS DEPARTMENT MAINTENANCE MANUAL
7. Grade 10GOP – Textbook Funds
8. 7808-e-facts sheet technician
10. A Consumer’s Guide to fnding the right Energy Efcient Vacuum Cleaners

The trainers who developed the Module (training material) preparation
No Name Qualification Educational Region College Mobile E-mail

background number
B.SC -Applied Electrical/Electronic
Technology
1 Tesfahun Ayalew Denigdine BGRS Assosa poly 0912132308 tesfugps44@gmial.com
M.Sc. -Electronics and comm Eng. TVET College
B.Sc - Applied Electrical/Electronic
Technology
2 Yidnekachew Regassa Hirpa Harari Harari poly 0910343909 Yidne888@gmail.com
M.Sc. - Electronic & communication TEVETCollege
Technology
B.SC – Electrical/Electronic Technology w/sihen Poly

TVET College
3 Mohammed Seid Hussen M.Sc – in electrical & communication Ahmara 0913174837 Tofikfuad606@gmail.com
Techno.mag,t
BS.C - Electronic & communication
Technology.
4 Berihun Belaynew mesganaw Oromia A. Mulugata 0912836044 berihunbelaynew@gamil.com
Boli Poly
TVET
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ELECTRICAL/ELECTRONICS

Module Title: Maintaining and Repairing Electric

Addis Ababa, Ethiopia

Page 2 of 94 Author/Copyright Maintaining and Repairing Training module Version -1

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AC..……………………………. Alternating current

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In Electrical/electronic equipment servicing filed; the Maintaining and repairing electric

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Figure 1.1 workshop organization

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1.2. Necessary tools and test equipment

Figure1.2 tools, test instruments

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Table 1.2 Personal Protective Equipment

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1.3. Set up and organize equipment’s

1.3.1. Setting Workplace for repair

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Sample Proper Arrangement and storage of tools and equipment

Figure 1.4 tools and equipment

Figure 1.6 Safe Workstation

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1.4. Repair & maintenance equipment

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 Preventive maintenance: - consists of mechanical, electrical, and electronic checks to

 Corrective maintenance: - isolates equipment failure by means of test techniques and

Maintenance and test procedures

Maintenance activities fall into three general categories:

Page 13 of 94 Author/Copyright Maintaining and Repairing Training module Version -1

 Acquire service manuals and service information required for repair

 Conduct complete check-up of electronically-controlled domestic appliances

 Document the identified defects based on check-up conducted

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This may include but not limited to:

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3. Make an initial inspection/ testing of the appliance.

customer’s Signature______________________ Date Repaired: ______________

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1. ---------------------- 2. -------------------3. ---------------------4. ---------------------5. --------------

Test III: Say true or false

Note: Satisfactory rating – above 60% Unsatisfactory - below 60%

Page 18 of 94 Author/Copyright Maintaining and Repairing Training module Version -1

Operation Title: Techniques for Preparing Workplace/equipment for maintenance

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Name: __________________________ Date: ____________

Time started: ____________________ Time finished: _______________

Task 1. Preparing Workplace/equipment for maintenance

Task 2 Verifying maintenance history with the company procedures

Task3 Acquiring Service manuals and service information

Task4 Setting Workplace for repair

Task 5 Preparing tools, test instruments and personal protective equipment

Page 20 of 94 Author/Copyright Maintaining and Repairing Training module Version -1

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Figure 2.1 step up transformer

Figure 2.2 Step Down Transformer

Page 22 of 94 Author/Copyright Maintaining and Repairing Training module Version -1

customer’s Signature________ Date Repaired:

Name: ______________ Date:

Time started: ______ Time finished: _