BORVEX · Operator guide
The machine has stopped. The wiring diagram is missing. What next?
Let's discuss the machine faultWhen a diagram is missing or out of date, we start with the machine’s actual condition. On-site electrical investigation helps establish the repair options and the conditions for carrying them out.
An older machine may have lost its wiring diagram, have pages missing, or have drawings that no longer reflect its actual condition. This can make repairs more difficult, but it does not in itself mean that an electrical fault cannot be investigated.
BORVEX helps investigate electrical and control-system faults on site in identifiable industrial machines already in use. We examine what can be established from the available information and the machine's actual condition, then determine the repair options and the conditions for carrying them out.
The possibility of troubleshooting without a diagram does not remove the need for the documentation required for safe use.
First, establish the facts
The two expressions do not mean the same thing.
Information needed to understand the electrical system is missing.
If the wiring diagram is missing, it is primarily information needed to understand the electrical system that is unavailable. Machine identification, operating instructions and other essential records may still be present. The significance of the missing diagram and whether it needs to be replaced must be established for the particular machine.
Operating, maintenance or conformity records may also be affected.
A ‘machine without documentation’ is a broader and inherently imprecise description. It may mean that one drawing is missing, or that instructions needed for safe use, applicable conformity records or information about previous modifications are also unavailable.
We therefore first establish exactly what is missing. If the machine's intended use, history or conditions for safe use cannot be clarified, the task goes beyond a routine electrical repair.
The manufacturer's complete technical file is a separate category: it is not the same as the operating and maintenance information to be supplied to the operator. The mere fact that the operator does not hold the manufacturer's full design records does not mean that all necessary machine documentation is missing.
Fault case · Siemens LOGO!
The machine stopped unpredictably, with neither a complete wiring diagram nor clear wire labels available. During on-site troubleshooting, we identified the failed component. After it was replaced, the control system operated reliably again.
The operator's perspective
The circuits need to be understood before targeted troubleshooting can begin. This can mean more work on site and downtime that is harder to plan.
Without a diagram, part of troubleshooting involves first understanding how the affected circuits work. Components must be identified, connections traced, and the behaviour at the time of the fault checked.
This may mean more work on site and downtime that is harder to predict. If the information uncovered is not retained, some of the same work will have to be repeated when another fault occurs.
The operational benefit can therefore be twofold: alongside identifying the cause of the present fault, more useful information may become available for future maintenance.
A lost diagram, unrecorded changes, an unavailable manufacturer or intermittent stoppages: the starting point is a known, identifiable machine.
For example, when:
A machine's age or country of manufacture does not by itself determine whether it can be repaired. We define the work we can undertake based on its condition, the available information and the conditions for safe working.
From investigation to the next step
We can identify the machine’s electrical fault even when no wiring diagram is available.
Investigating the electrical fault. We look for the cause of the symptom by tracing the affected circuits, taking measurements and examining control components.
An agreed intervention that addresses the identified fault.
Determining and carrying out the required repair. If the fault can be identified, the intervention is technically feasible and can be carried out safely, and the necessary parts or access are available, we agree the repair with you.
Drawings, parts lists or notes within the agreed scope.
Documenting the electrical condition established. Within a separately agreed scope, we can prepare circuit diagrams, parts lists or maintenance notes. The material supplied clearly distinguishes the parts examined, the relationships verified and the points still requiring clarification.
What can be repaired, and where are more information or specialists needed?
Clarifying the next step. If repair requires the manufacturer's involvement, additional documents, a separate inspection or another specialist discipline, we will indicate this.
Recording the observed condition can also support the next repair. We clearly define the scope of the partial drawing and the verified connections.
A usable diagram helps explain the purpose of each component, how circuits are connected and where earlier work has been carried out.
This can make future troubleshooting, component identification and maintenance handover to another specialist easier. The plant is less dependent on the same technician remembering the details of an earlier repair.
The drawing must reflect the actual condition. An outdated or unverified drawing can lead troubleshooting in the wrong direction. A partial drawing prepared on site applies only to the scope and verified condition identified on it; it does not automatically become documentation for the entire machine.
We discuss the machine data, the fault and the available documents. After the inspection, we clarify together which repair is feasible and what remains open.
First we discuss the machine details, symptoms and available records. We then define the first steps and scope of the on-site investigation.
Based on the investigation, we explain what can be repaired, what needs further investigation and which documentation or technical obstacles remain. The scope of any additional work is agreed separately.
Without a diagram, the time required and the outcome of a repair cannot always be estimated in advance.
Contact us
Even if the machine documentation is incomplete or unavailable altogether, it is worth getting in touch.
Tell us the machine’s manufacturer and model, the fault symptoms and the site location. Available records and a safely taken photo can help with the initial discussion.
On-site work: Somogy · Baranya · Zala
Let's discuss the machine faultDo not remove machine covers or open electrical cabinets to take photographs.
This page provides general information. The work that can be undertaken on a particular machine and the scope of the documentation to be supplied are determined by an individual assessment and agreement.