CASE STUDY ON

“TROUBLESHOOTING AND MAINTENANCE OF PCB BOARDS

&CONTROLLERS”

Case Study submitted in partial fulfillment of the requirements to complete

term work of Skill Development Of Third Year Engineering in the
Department of Electronics and Telecommunication Engineering.

Submitted By
Name. Roll No.
1.] Insha Momin
47

Under the Guidance Of Prof. Manjusha Patil

Electronics and Telecommunication Engineering

Ajeenkya D.Y. Patil School Of Engineering

Dr D.Y. Patil Knowledge City, Charholi (Bk), Via Lohegaon,
Pune-410501

YEAR: 2025 - 2026

0
 “Empowerment through quality technical education”
AJEENKYA D Y PATIL SCHOOL OF ENGINEERING
Dr. D. Y. Patil Knowledge City, Charholi Bk., Via. Lohegaon, Pune –
412 105.
Department of E&TC Engineering

Sr. No. Experiment Page No.

1 Troubleshooting and maintenance of PCB Boards & 2-7

Controllers.

Case Study on the Study, Testing, and

8 - 11
2
Maintenance of Batteries

12 - 15
3 Design a web page(s).

16 - 19
4 Troubleshooting and maintenance of Power Supplies

1
 "Empowerment through quality technical education"
AJEENKYA D Y Patil School of Engineering
Dr. D. Y. Patil Knowledge City, Charholi Bk., Via. Lohegaon, Pune – 412 105

Department of E&TC Engineering

Experiment No. 1
Title: Troubleshooting and maintenance of PCB Boards & Controllers.

Date of Performance: Roll No:

Date of Submission: University Seat No:

Signature of Staff:

2
 Experiment No. 1

Aim: Troubleshooting and maintenance of PCB Boards &Controllers.

Skill Set: Testing /Measurement/Calibration/Troubleshooting/Maintenance/Installation

Theory:

 Troubleshooting and Maintenance of PCB Board and Controllers

PCB Board:
A printed circuit board (PCB) is a foundational component in electronics, serving as a physical platform
to mount and connect electronic components, enabling them to function as a [Link] and
maintaining PCBs (Printed Circuit Boards) involves a systematic approach, starting with visual inspection
and progressing to electrical testing and component-level analysis.

Troubleshooting:
1. Visual Inspection:
 Check for physical damage: Look for burn marks, cracks, lifted components, or corrosion.
 Examine solder joints: Ensure they are shiny and well-formed, not dull or cracked.

2. Component Testing:
 Use a multimeter: Check for shorts, opens, and
resistance values of individual components.
 Test integrated circuits (ICs): Ensure theyare
receiving the correct power and signals.

3. Power Supply Issues:

 Verify voltage levels: Ensure the power supply is
providing the correct voltage to the board.
 Check for ripple and noise: These can indicate power supply problems.
4. Short Circuit Detection:
 Use a multimeter: Check for low resistance between different points on the board.
 Consider thermal imaging: A thermal camera can help pinpoint short circuits by detecting heat.

5. Advanced Techniques:
 Functional testing: Simulates the intended use of the board to verify its functionality.
 Flying probe testing: Automated testing that uses probes to contact different points on the board.

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 Maintenance:
 Visual Inspection:
Regularly check the PCB for signs of damage, such as cracks, burns, or corrosion.
 Cleaning:
Remove dust and debris using compressed air, ensuring it's done safely and effectively.
 Component Check:
Ensure all components are securely attached and
functioning correctly. Look for signs of overheating or
damage.
 Environmental Control:
Maintain proper temperature, humidity, and ventilation
to prevent damage from environmental factors.
 Preventive Measures:
Implement regular maintenance schedules and address potential issues early to avoid major problems.
 Repair:
If issues are found, address them promptly using appropriate tools and techniques. Consider seeking
professional help for complex repairs.

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Troubleshooting and Maintenance of Controller:

Controller:
Troubleshooting and maintaining controllers involves a systematic approach to identifying and resolving
issues, ensuring optimal performance and longevity. This includes regular checks of power supplies,
wiring, sensors, and communication, as well as software updates and backups.

Figure 1.3: Initial Inspection for any defects

Troubleshooting:
1. Initial Inspection:
 Power Supply: Ensure the power supply is functioning correctly, checking for indicator lights
and loose connections.
 Wiring: Inspect all wiring for damage, loose connections, and proper grounding.
 Environmental Factors: Check for excessive heat, humidity, or dust, which can affect controller
performance.
 Indicator Lights: Observe the controller's indicator lights (power, run, I/O) to identify potential
problems.
2. Input/Output Devices:
 Inputs: Verify that sensors, switches, and other input devices are connected properly and
functioning as expected.
 Outputs: Check for proper operation of actuators, relays, and other output devices.

3. Controller-Specific Checks:
 Communication: Ensure communication cables and connections are secure and functioning
correctly.
 Software: Check for any software glitches or errors, and consider performing a software reset or
update.
 Firmware: Ensure the controller's firmware is up to date.
4. System Analysis:
 Error Logs: Review error logs or diagnostic information provided by the controller or associated
software.
 Process Simulator: If available, use a process simulator to test the control logic and identify
potential issues.

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Maintenance:

1. Regular Cleaning:
Clean the controller's surface, buttons, and knobs to prevent dust and debris buildup.

2. Firmware and Software Updates:

Install updates to improve performance e and address potential vulnerabilities.

3. Backup and Documentation:

Regularly back up the controller's configuration and maintain thorough documentation.

4. Preventive Maintenance:
Implement a preventive maintenance schedule to identify and address potential issues before they cause
failures.

Conclusion:

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Questions:

1. What are the key steps involved in visually inspecting a PCB during troubleshooting?
Key visual inspection steps include checking for physical damage like burn marks, cracks, or
corrosion, and examining solder joints to ensure theyare shiny and intact, not dull, cracked, or lifted.

2. How can a multimeter be used to detect short circuits on a PCB?

A multimeter can measure resistance between different points on the PCB. Low or zero resistance
may indicate a short circuit. This helps identify unintended connections or faults in the circuit.

3. What preventive maintenance practices help extend the life of a PCB?

Preventive practices include regular visual inspections, cleaning dust and debris with compressed
air, checking components for secure attachment and heat damage, controlling the operating
environment, and following scheduled maintenance routines.

4. What should be checked first during initial troubleshooting of a controller?

Initial checks should focus on the power supply (ensure it's working and connections are secure),
wiring (look for damage or loose connections), environmental conditions (like heat or dust), and
indicator lights for error signals.

5. Why is regular firmware and software updating important for controllers?

Regular updates improve controller performance, fix software bugs, and address security
vulnerabilities. Keeping firmware and software current ensures stable and efficient operation of the
control system.

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 "Empowerment through quality technical education"
AJEENKYA D Y Patil School of Engineering
Dr. D. Y. Patil Knowledge City, Charholi Bk., Via. Lohegaon, Pune – 412 105

Department of E&TC Engineering

Experiment No. 2
Title: Case studies on Study, Testing and maintenance of Batteries.

Date of Performance: Roll No:

Date of Submission: University Seat No:

Signature of Staff:

8
 Experiment No. 2

Aim: Case studies on Study, Testing and maintenance of Batteries.

Skill Set: Testing /Measurement/Calibration/Troubleshooting/Maintenance/Installation

Theory:

1) Batteries
Lithium-ion batteries are the primary energy storage system in electric vehicles due to their
high energy density and efficiency. Understanding battery behavior under real-world conditions
is crucial for improving battery life, safety, and performance

2) Testing

a) Capacity Testing

 Periodic full charge-discharge cycles under controlled laboratory conditions to measure capacity
fade.

b) Electrochemical Impedance Spectroscopy (EIS)

 Applied to detect increases in internal resistance and identify aging mechanisms like solid
electrolyte interphase (SEI) growth.

c) Thermal Imaging and Temperature Monitoring

 Used to detect hotspots and uneven heating during charge/discharge cycles.

d) Accelerated Aging Tests

 Batteries subjected to high-rate cycling and elevated temperatures to simulate long-term usage in
shorter times.

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Maintenance

 Implement thermal management systems (liquid cooling/heating) to maintain battery

temperatures within an optimal range (20-40°C).
 Encourage partial charging and avoid full 0-100% cycles when possible.
 Use smart BMS to monitor cell voltages, temperatures, and balance charge actively.
 Schedule periodic capacity testing during vehicle service to monitor battery health.

Conclusion:

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Questions:

Q1. Why are lithium-ion batteries commonly used in electric vehicles (EVs)?
Lithium-ion batteries are used in EVs because they offer high energy density and efficiency,
which are essential for maximizing vehicle range and performance. They also support multiple
charge-discharge cycles, making them suitable for long-term use in mobility applications.

Q2. What is the purpose of capacity testing in lithium-ion battery analysis?

Capacity testing involves performing full charge-discharge cycles under controlled conditions to
measure capacity fade over time. This helps assess battery degradation and predict the remaining
useful life of the battery.

Q3. How does Electrochemical Impedance Spectroscopy (EIS) help in battery testing? EIS
helps by detecting increases in internal resistance, which can indicate aging mechanisms like the
formation of a solid electrolyte interphase (SEI). It’s a diagnostic tool to analyze battery health
without fully cycling the battery.

Q4. What are the key maintenance practices to prolong battery life?
Key practices include:
Maintaining battery temperature between 20–40°C using thermal management systems. Avoiding full
charge/discharge cycles (0–100%) and using partial charging strategies.
Employing smart Battery Management Systems (BMS) to monitor and balance cells. Conducting
regular capacity testing during vehicle servicing.

Q5. Why are thermal imaging and temperature monitoring important in battery testing?
Thermal imaging and temperature monitoring help detect hotspots and uneven heating during
operation, which can indicate issues like cell imbalance or internal faults. Early detection can
prevent failures and improve safety and performance.

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 "Empowerment through quality technical education"
AJEENKYA DY Patil School of Engineering
[Link] Knowledge City ,Charholi Bk.,[Link],Pune–412105

Department of E&TC Engineering

Experiment No. 3

Title: Case study on design a web pages.

Date of Performance: Roll No:

Date of Submission: University Seat No:

Signature of Staff:

12
 Experiment No. 3

Aim: To Design a web pages.

Theory:
Web pages are web documents that can be viewed through a web browser. It typically
comprises content, pictures, recordings, and intuitive components. Web pages are
composed in HTML (Hyper Text Markup Dialect) and styled with CSS (Cascading Style
Sheets). They may moreover incorporate scripts composed in a language like JavaScript to
include usefulness. Web pages are facilitated on servers and gotten to through URLs
(Uniform Resource Locators).

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Conclusion:

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 "Empowerment through quality technical education"
AJEENKYA DY Patil School of Engineering
[Link] Knowledge City ,Charholi Bk.,[Link],Pune–412105

Department of E&TC Engineering

Experiment No. 4
Title: Troubleshooting and maintenance of Power Supplies

Date of Performance: Roll No:

Date of Submission: University Seat No:

Signature of Staff:

15
 Experiment No. 4

Aim: Troubleshooting and maintenance of Power Supplies

Skill Set: Testing /Measurement/Calibration/Troubleshooting/Maintenance/Installation

Theory:

 Troubleshooting and maintenance of Power Supplies

A power supply is an electronic device that provides electrical power to a load by converting one
form of electrical energy to another. Its main function is to convert high-voltage AC from an outlet
into the low-voltage DC required by most electronic components.

Linear Power Supply: Uses a transformer, rectifier, filter, and linear regulator. They are simple, reliable,
and have low ripple, but are often bulky and less efficient.
Linear Power Supply: This type of power supply uses a four-stage process to convert AC to DC:

 Transformer: Steps down the high AC voltage from the wall outlet to a lower, safer AC voltage.
 Rectifier: A circuit, typically using diodes, that converts the stepped-down AC voltage into a
pulsating DC voltage.
 Filter: A capacitor-based circuit that smooths out the pulsating DC, creating a more stable, but
still rippled, DC voltage.
 Voltage Regulator: An electronic circuit that maintains a constant output voltage, regardless of
changes in the input voltage or the load, providing a clean and stable DC supply.

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Switching Mode Power Supply (SMPS):

This type is more efficient and compact because it rapidly switches a power transistor on and off at high
frequencies (typically 20 kHz to 500 kHz). This switching action allows for precise voltage regulation
with minimal power loss. The SMPS rectifies the AC input directly, then chops the resulting DC into
high-frequency pulses. A small, high-frequency transformer then steps the voltage up or down, followed
by another rectification and filtering stage to produce the final DC output.

Troubleshooting

Troubleshooting a power supply involves a systematic approach to identify the root cause of a failure.

1. Initial Inspection
 Visual Check: Look for signs of physical damage, such as burnt components, or broken solder
joints.
 Listen for Sounds: Listen for unusual sounds like hissing or clicking, which can indicate a faulty
component.
 Smell: A burnt smell often points to an overloaded or shorted component.

2. Power and Voltage Checks

 Input Power: Verify that the power supply is receiving the correct input voltage.
 Output Voltage: Use a multimeter to measure the DC output voltage in both loaded and unloaded
states. A reading that is too high, too low, or unstable indicates a problem.

3. Component-Level Testing
 Fuses: Check the fuse for continuity with a multimeter. A blown fuse often indicates a short
circuit.
 Capacitors: Test for shorts, leaks, or open circuits. Bulging or leaking capacitors are a clear sign
of internal failure.

4. Advanced Diagnostics
 Oscilloscope: Use an oscilloscope to check for voltage ripple and noise on the output. Excessive
ripple can indicate a failing filter capacitor.

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Maintenance

Regular maintenance can extend the life of a power supply and prevent unexpected failures.

1. Cleaning
Dust Removal: Regularly clean the power supply and its fans using compressed air to remove dust and
debris. Dust acts as an insulator and can lead to overheating.

2. Environmental Control
Ventilation: Ensure proper ventilation and avoid blocking vents.
Temperature and Humidity: Operate the power supply within its specified temperature and humidity
ranges.

3. Preventive Checks
Visual Inspection: Conduct periodic visual inspections for signs of stress or damage.
Fan Check: For power supplies with fans, ensure the fan is spinning freely and quietly.

4. Component Replacement
Scheduled Replacements: In high-reliability applications, consider replacing components with a limited
lifespan, such as electrolytic capacitors, before they fail.

Conclusion:

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 Questions:
1. What are the common symptoms of a faulty power supply?
Answer:
 Computer or equipment not turning on
 Random shutdowns or restarts
 Burning smell or unusual noise (buzzing, clicking)
 Output voltage fluctuations
 Overheating of the supply unit

2. What are the first steps in troubleshooting a power supply?

Answer:
 . Check input power connection and fuse.
 Measure the output voltages with a multimeter.
 Inspect visually for burnt components, bulging capacitors, or loose wires.
 Verify cooling fans are working.
 Swap with a known good power supply (if available) to confirm the issue.

3. What preventive maintenance practices should be followed for power supplies?

Answer:
 Regularly clean dust using compressed air.
 Ensure proper ventilation and cooling.
 Check and tighten electrical connections.
 Periodically test output voltage and current.
 Replace aging capacitors and fans before failure.

4. What safety precautions should be taken during power supply maintenance?

Answer:
 Always switch off and disconnect from mains before working.
 Discharge high-voltage capacitors before handling.
 Use insulated tools and wear protective equipment.
 Avoid touching live circuits.
 Follow manufacturer’s service manual and guidelines.

5. Why is troubleshooting and maintenance important in power supplies?

Answer:
 Ensures reliability and stable performance of devices.
 Prevents damage to connected equipment.
 Increases lifespan of the power supply.
 Reduces downtime and repair costs.
 Helps maintain safety by avoiding electrical hazards.

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