IMEE, CHAPT-7

TROUBLE-SHOOTING
It is the process of analysing the behaviour or operation of a faulty circuit to determine what is wrong
with the circuit. It then involves identifying the defective components and repairing the circuit.
Any electrical machine or equipment can be used to be working normal if voltage across the machine
is rated voltage, current drawn is within the safe limit, frequency should not vary beyond the permissible limit,
running at its normal speed, temperature rise is within the range of permissible limit and it should not have
un usual noise etc. Successfully trouble shooting a complex piece of electrical equipment gives a tremendous
sense of satisfaction. It presents an overview of a simple but effective method of investigating an electrical
problem. Electrical trouble shooting of an electrical equipment can be analysed in seven steps
1. Gather information
2. Understand the malfunction
3. Identify which parameter need to be evaluated
4. Identify the source of the problem
5. Correct/repair the component
6. Verify the repair
7. Perform root cause analysis
The operation of electrical machine above or below the rated voltage, current, temperature and
speed is responsible for poor performance. Trouble in electrical apparatus is generally caused by
ground faults, short circuit fault or open circuit faults. A ground fault is an electrical connection
between the wiring of the equipment and its frame. A short circuit is a connection which by pass part
or all of an electric circuit. An open circuit is a break in the continuity of the circuit.
CAUSES OF FAULT IN ELECTRICAL EQUIPMENTS:
Abnormal operation or causes for failure of electrical equipment can be classified as internal causes
and external causes.
The internal causes for failure of equipment are mostly due to the failure of insulation, which
may be due to the following reasons:
1) Temperature rises above permissible limit for a long time due to prolong overloads.
2) A short circuit fault in winding.
3) A phase to ground fault resulting into large fault current.
4) In case of three phase induction motor, an open circuit fault in one phase, other two
phases supplying the loads.
5) Rotor faults.
6) Failure of bearings, will result in to more frictional loss and increases the temperature
rise.
7) Magnetic locking between the stator and rotor.
8) Uneven air gap.
9) Shorted turns of phase windings. These are the most probable causes which may result
in to failure of equipment operation or developing abnormal working condition.
Following are the main reasons for external causes.
1) Sustained overload on the equipment
2) Single phasing from supply side.
3) Unbalanced supply voltage which results in heating due to negative phase sequence
currents.
4) Over voltage or under voltage
5) Change in supply frequency
6) Short circuit fault in supply system.
 Every Engineering industry should maintain a trouble shooting chart or repair, maintenance and
preventive maintenance as well as break down maintenance chart- which will consist of maintenance record
of each and every machine which may be maintained either in the form of a detailed form or register. This
type of records is of great help in ensuring that periodical maintenance works are carried out according to
scheduled laid down and also it gives information about the cause of long standing complains of
unsatisfactory operation.

The troubleshooting chart should consist of history of every electrical equipment. It should consist
of:

i) Name plate details of the machine, such as rating, voltage, current, speed, makers name,
Serial No. etc.
ii) Date of installation and insulation resistance value at the time of installation, air gap etc.
iii) The maintenance chart should consist of Columns for preventive maintenance observations
i.e monthly, quarterly, half-yearly, yearly etc.
iv) It should consist a column for break down maintenance, type of fault, maintenance carried
out, parts replaced etc. should be clearly recorded.

TROUBLE SHOOTING TECHNIQUES

The two-basic way of detecting circuit faults are: (a) Visual inspection and (b) Testing

Visual Inspection: This is very important as approximately 90% of faults can be found by this
inspection alone. It involves smelling, pulling on leads, tapping the appliance, shaking, turning some
parts.

When observing malfunctioning equipment, look for visual signs of mechanical damage such as
indications of impact, chafed wires, loose components or parts laying in the bottom of the cabinet.
Look for signs of overheating, especially on wiring, relay coils and printed circuit board.

Testing: The following tests can be conducted to trouble shoot the faults

(a) Voltage test using Meters: Voltage of circuit, equipment can be checked using either Voltmeter
or digital/ analog multimeter.
(b) Current test using Meter: Use of analog/ digital Multimeter (DMM) for measurement of current.

COMMON FAULTS IN DOMESTIC ELECTRIC APPLIANCES:

Faults may be in supply cord or in appliance it self.
1. Supply cord faults (a) Break in wires
(b) short circuit between wires
2. Appliance faults (a) Break in load circuit
(b) Short circuit between load terminals
(c) Short between load to the body of appliance
 TROUBLE SHOOTING CHART FOR D.C MACHINES
a. DC MOTOR/MACHINES
S.N TROUBLES
1 Motor will not start
2 Supply or starter trips
out at start
3 On starting it starts
then changes
direction of rotation
4 Slow running
5 Motor runs fast or at
high speed.
6 Motor runs very slow
7 Motor overheating
8 Sparking at brushes
CAUSES
1.Blown fuse
2.Shaft jammed
3. Shunt field open
4. Open armature circuit
5. Brushes are not making
contact with commutator
6.Bearing is seized
7.Current is not available
8. Fault with supply
9. Motor or load locked up
10. wrong connection in
control circuit
1.Wrong or loose connection
2.Motor overloaded
3.Inertia of load too high
4.overload or circuit breaker
incorrectly set or seized.
Reverse polarity of DC
supply.
1.low voltage
2.overload
3.Starting resistance has not
been completely cut out.
4.Armature bars shorted
5.Neutral not available
1. Voltage available is more
than rated voltage.
2. Load is less.
3. Shunt field coil is shorted.
4.Shunt field coil is reversed.
1. Low voltage
2.Over loaded
3.Armature bars shorted
1.Drawing more current due
to overloaded.
2.Ventilation is defective.
3. Shorted coils.
1. Incorrect neutral/negative
2.Shorted commutating pole
turns.
3.Open circuited coils.
4.Poor soldered connections.
REMEDIES
1. Test the fuse with ohmmeter with
circuit load.
2. Check bearing & its lubrication.
3. Locate the defect in shunt field
circuit.
4. Inspect commutator for partial
burning.
5.Adjust the springs, in case brushes
are worn out, replace them.
6. Replace or repair the bearing
7.Check starter
8. Check the supply
9.Remove clamps locks etc
10. short out control circuit
1.Fix up connections
2.change motor for correct size
3.change cable for correct size
4.correct setting of overload or
breaker or change
Check generator for the reason of
changing polarity.
1. Check for correct voltages
2.Check bearings, check for excessive
load.
3.Starter needs thorough checking.
4.For burnt coils and black
commutator bars it should be
repaired/replaced.
1.Ensure rated voltage
2.Increase the load or put fixed
resistance in armature circuit.
3.Replace it by new coil
4. Connect the coil correctly.
1.Check for correct voltages
2.Check bearings, check for excessive
load.
3. Get the motor repair shop.
1.Reduce load by reducing speed.
2. Check up the ventilation
3. Repair the windings.
1.Correct the neutral according to
manufacturer settings.
2.Repair the coils.
3.Repair the coils.
4.Resoldere them properly.
 9 Field winding get hot 1. Voltage is more than rated
voltage.
2.ventilation is defective.
Brushes are getting 1. Brushes too soft
worn out very fast. 2. Commutator is found to
be rough.
3.Moisture
11 Unusual vibration 1.Mis-alignment
which may indicate 2.Pulley eccentric or loose.
unbalance. 3.Bent shaft
4.Foundation incorrect
12 Giving unusual noise 1. Brush singing or chattering
2.Mounting is loose
3.Laminations of armature is
loose.
4.Armature is rubbing the
pole faces.
5.Mechanical vibration
including noisy bearing.
B. TROUBLESHOOTING CHART OF AC MOTOR:
S.N TROUBLES CAUSES
1 Motor will not start 1.Fault in supply
2.Motor or load locked up.
3. Wrong connection in control
circuit.
2 Supply or started 1. Wrong or loose connections.
trips out at start. 2.Motor overloaded.
3.Overload or circuit breaker
incorrectly set or sized.
3 Motor start but has 1.Incorrect connections.
no torque. Motor 2.Delta wound motor connect
does not reach full in star.
speed or takes a long 3.Inertia of load to high.
time to accelerate. 4.Motor overloaded.
5.Low voltage due to voltage
drop.
1.Ensure correct voltage.
2.Remove the restrictions which are
responsible for bad ventilation.
1.Replace the brushes with the
recommended grade of brushes.
2.Grind its face.
3. Protect the motor from moisture or
replace it by enclosed motor.
1.Re-align
2.Tighten/correct the pulley on shaft
3.Straghten the shaft or replace it.
4.Add shims and level the foundation.
1.Brush angle is required to be
checked, Re-surface the commutator
and brush.
2.Tighten foundation bolts.
3. Replace the core.
4. Re-align the rotor.
5.Find the causes and take remedial
measures. Replace or repair the noisy
bearings if required.
REMEDIES
1. Check for correct voltages at motor
terminals. Fit new fuses reset circuit
breakers etc.
2. Make sure motor and load are free
to run.
3. Check to ensure contactors operate.
1.Check all lugs are properly crimped
or soldered, and connections are tight.
2.Check load performances data
against motor performance data.
3.Check setting of overload and circuit
breakers and allow for starting
current.
1.Check connection diagram.
2. change the connections.
3. Check load performance data
against motor performance data.
4. Remove the load.
5.Measure voltage at motor terminals
while motor starting.
4 Motor overheating 1. Motor overloaded.
2.Ineffective cooling.
3.Dirt on the winding.
4.Wrong connections.
5. Wrong voltage of frequency.
6.Supply voltage unbalanced.
7.Motor single phasing.
5 No load amps in 1.Incorrect connections.
excess of full load 2.Star wound motor
amps. connection delta.
3.Voltage in excess of
nameplate.
4.Motor supplied for different
voltage or frequency.
6 Mechanical noise or 1.Thrust from load or mis-
vibrations noisy, alignment.
vibrations bearings 2.Rotor pulling or foreign
overheating matter in air-gap.
3.Damaged bearing.
4.Out of balanced load,
coupling or pulley.
5.Excessive belt pull.
6.Motor foundation not rigid.
7.Too much grease, no grease
or foreign matter in grease.
7 Motor amps in excess 1.Motor overloaded.
of nameplate full 2.Low supply voltage.
load amps on load. 3.Wrong voltage or frequency.
4.Wrong connections.
5.Motor single phasing.
6.Supply voltage unbalanced.
7.Motor speed not matched to
load.
8 Excessive noise 1.Wrong connections.
2.Wrong voltage
3. Motor single phasing.
9 Unbalance amps in Unbalanced supply voltage
different phases
when motor loaded.
10 Motor runs in wrong Wrong connections
direction.
1.Remove load.
2.Check fan and airflow and
temperature of air.
3.Clean the windings.
4.Check connection diagram.
5.Check nameplate.
6.Measure phase to phase voltage
accurately.
7.Check volts and amperes in all three
phases.
1.Check connections.
2.Check connection diagram.
3.Measure voltage at motor terminals.
4.Compare supply voltage and
frequency to nameplate.
1.Check gap between coupling halves
and alignment.
2.Turn shaft slowly by hand and feel
for roughness or stiffness. Check for
bent shaft or fan rubbing.
3.Remove the bearings.
4.Run motor disconnected from load
and then with pulley or coupling
removed.
5.Run motor without belts.
6.Check design and construction
foundations.
7.Check the proper amount of grease.
1.Check load
2.Measure voltage at motor terminals.
3. Check nameplate.
4.Check nameplate.
5.Chgeck volts and amps in all three
phases.
6.Check voltage.
7.Measure motor speed and check
load speed requirements.
1.Check connections.
2.Check voltage with nameplate
3. Check voltage with amps in all three
phases.
Measure phase to phase voltage
accurately.
Watch shaft rotation.