Lec # 015 Principles of Troubleshooting

Principles of Troubleshooting
NOORNABI SHAIKH
ASSISTANT PROFESSOR
MUET
INTRODUCTION
All electrical equipments are designed to operate safely within

specified limits of speed, voltage, current and temperature.
Under normal conditions, the construction and general
arrangement of electrical equipment ensure safe and efficient
operation.
The performance of the equipment is affected if the machine

do not operate within specified limits. Therefore it is necessary
to detect any trouble, causing abnormal operation of the
equipment, and correct it so that the machine will continue to
operate efficiently for a long period.
2 MDET/NNSHAIKH/TROUBLESHOOTING
Continue….
Troubles can be:
 detected by sight – such as failure of starting of a

motor, sparking at brushes etc.
 detected by hearing – such as humming noise,
mechanical noise etc.
 detected by touch – such as vibrations, overheating
of windings, brushes etc.
Systematic analysis of the reasons for failure of the equipment

or its abnormal operation is called “TROUBLESHOOTING”.
There are two types of troubles:
1. MINOR TROUBLES
These troubles are relatively simple and can be detected
easily. The equipment may be restored for normal working
within a short duration. Some minor troubles are:
a) Blown fuse
b) Loose connections
c) Improper adjustments of brushes
d) Overload etc.
2. MAJOR TROUBLES
To identify major troubles an engineer has to apply his technical

knowledge of plant in a logical fashion.
After finding the probable trouble, it is necessary to conduct a

few diagnostic tests to confirm the conclusions.
The most serious result of a major un cleared fault is fire which

may not only destroy the equipment of its origin but may
spread in the system and cause total failure.
The most common type of major fault witch is most dangerous

one is the “short circuit”.
Problem Solving Analysis
Before attempting to service a device, one must first develop

an understanding of problem solving and how this concept
applies to overall troubleshooting and repair.
Therefore servicing a device can be dividing into 3 – phases:
1. Situational Analysis
2. Problem Solving
3. Decision Making
One must proceed in this logical manner; otherwise mistakes, accidents,

wasted time, and expense might result.
For example, many troubleshooter, upon the discovery of a blown fuse,
will just replace the fuse only to have another fuse blow. Instead the
troubleshooter
6 should first determine the source of the problem.
MDET/NNSHAIKH/TROUBLESHOOTING
 Situational Analysis
This is the 1st step in servicing a device. It involves critical

scrutiny and analysis of a problem situation.
It is defined as simply looking at the overall condition of the
device and determining whether a problem even exists or not.
Begin this 1st step by asking questions and making observation
as follows:
 Discuss the defect with the owner or operator.
 Compare the problem with past experiences.
 Consider the possibility that there is no problem at all, its an operating
error.
 Identify the existing state of operation with the desired state
 Make an overall observation of the situation, noting symptoms and
relevant changes.
7
 Problem Solving
This is the 2nd phase and is completed when it has been
determined through situational analysis that a problem exists that
needs further investigation.
Problem is defined as a deviation from a standard or a desired
state. Examples include malfunctioning or inoperable device.
Troubleshooting is the process of problem solving. It is in this
phase that the cause of a problem is identified.
The first step in problem solving is getting organized.
 Start by obtaining necessary schematics, manufacturer’s

specifications and servicing manuals, tools and equipment.
DO NOT SHORT CHANGE THIS STEP BY WASTING A LOT OF TIME

ATTEMPTING TO REPAIR A DEVICE.
READING
8 THE SERVICING GUIDE COULD EASILY SOLVE PROBLEM
In other words:
“Those who fail to plan, plan to fail”
The second step: Ask following question
 Describe the problem condition.

 Compare the problem situation with the known operating condition
prior to the breakdown.
 Describe all known differences such as the symptoms, noises, and
smells noticed when the defect occurred.
 Compare the “what is” with the “what is not”. Which of the components
Are okay and which are not, and to what degree are the components
are defective.
 Analyze differences through testing by paying close attention.
Once the actual cause of problem is determined, one is ready to

9
proceed the final stage “Decision Making”.
 Decision Making
It is defined as examining various solutions or alternatives and

selecting best option.
When deciding what alternative to implement, consider all the

advantages and disadvantages for each alternative along with
contingency planning.
Contingency planning takes into account future changes in the

overall system, such as expected life, operating conditions, and
model changes.
For example: it might not be wise to replace the motor with a

new one when you suspect the entire system might soon be
obsolete and replaced anyway.
REMEMBER
ALWAYS FOLLOW THE 3 – PHASES
 SITUATIONAL ANALYSIS
 PROBLEM SOLVING (Troubleshooting)
 DECISION MAKING (Repair)
Follow these basic stages and understanding the

importance of this sequence is essential to becoming a
skilled expert.
Circuit faults
Most breakdowns are directly or indirectly result of
operating abuse or lack of maintenance.
Some basic causes of electrical / electronic breakdowns
are:
 Heat
 Moisture
 Dirt & Contaminants
 Abnormal or Excessive Movement
 Poor Insulation
 Manufacturing Defect
 Animals & Rodents
Heat increases resistance of the circuit, which in turn increases the
current. It also causes material to expand, dry out, crack, blister,
and wear down much more quickly; sooner or later, the device will
break down.
Moisture also causes circuits to draw more current and

eventually breakdown. Moisture (water and other liquids) causes
expansion, warping, quicker wear, and abnormal current flow
(short circuit)
Dirt and contaminants such as fumes, vapors, abrasives, soot,
grease, and oils are materials that cause electrical / electronic
devices to cog or gum up and operate abnormally until they finally
break down.
Abnormal or excessive movement can lead to breakdowns.

Vibrations and physical abuse are the leading causes of these types
of breakdowns.
Poor insulation is often the work of an unqualified installer or
one who is careless or in a hurry. Failure to tighten a bolt or
properly solder a connection results in an electrical / electronic
device breaking down prematurely.
Manufacturing defects are also common. For example loose

circuit board after delivery and installation. The shipping and
transportation can also loosen or damage circuit boards and
components.
Animals and rodents can also be the cause of electrical /

electronic breakdowns. A rat or other small rodents might chew on
an electrical wire or find its way into a motor.
It is essential that every troubleshooter understand the 4
most common causes of circuit faults
1. SHORT
2. OPEN
3. GROUND
4. MECHENICAL
TYPICAL SIGNS OF SHORT CIRCUIT
 Blown Fuses
 Increased Heat
 Low Voltage
 High Amperage
 Smoke
TYPICAL SIGNS OF OPEN CIRCUIT
 Infinite Resistance
 Zero Amperage
 Device Completely Dead
TYPICAL SIGNS OF GROUND FAULTS ARE
 Abnormal Amperage Reading

 Abnormal Voltage Reading
 Abnormal Resistance Reading
 Shocks
 Abnormal Circuit Performance
 Tripped Ground Fault Interrupters
 Periodic Blown Fuses / Circuit Breakers
TYPICAL SIGNS OF MECHANICAL FAULTS ARE
 Noisy Operation
 Abnormal Operation
 Visual Inspection
 Circuit Failure
Difference Between Ground Fault & Short Circuit Fault
Generally, the short circuit causes the device to

stop operating and trips a CB due to the direct
bypass.
In the grounded circuit, the device often keeps

operating due to the indirect circuit bypass, but
operates poorly and draws abnormal currents and
voltages.
The grounded circuits can be the most dangerous,
because the device often keeps functioning; the
operator can experience shocks, especially without
proper ELCBs
The most important tool or instrument a troubleshooter can
use is his / her own senses. Most troubleshooting problems
can be found by the use of one or all of the senses:
 SIGHT
 SMELL
 TOUCH
 HEARING
Troubleshooting Methods
There basic techniques common to all troubleshooters when servicing
electrical / electronic devices are;
 Voltage Measurements
 Amperage Measurements
 Resistance Measurements
 Substitution Type of technique
 Bridging the troubleshooter
uses depends on
 Heat the type of defects
or symptom exists.
 Freeze
 Signal Tracing / Injection
 Component Testers, Test Lamps
 Resoldering, Adjusting, Etc.
22  Bypassing MDET/NNSHAIKH/TROUBLESHOOTING
The Voltage Measurement:
It can be done by using a voltmeter or oscilloscope. A zero voltage reading
might indicate an open circuit, while low voltage reading might indicate a
shorted component. Remember always connect a voltmeter in parallel with
the circuit.
The Amperage Measurement:

It can be taken by using an ammeter or a “clamp – on” ammeter. The
ammeter indicates and locates common circuit faults, such as shorts, opens,
and grounds. Remember, always connect the ammeter in series with the
circuit when measuring current.
The Resistance Measurement:

An ohmmeter is used to measurement the continuity , resistance of a circuit,
or resistance of the component. This technique is very valuable in locating
shorts, grounds, and open circuits. Remember, always shut off the power
before measuring resistance
The Substitution Technique:
This means replacing a suspected faulty component with a known good
component. However, there are some risks involved. If a circuit board is
replaced with a new one and the underlying problem is not the circuit board,
damage might result to this replacement part.
Bridging:
If troubleshooter suspects a component (usually a capacitor) to be faulty,
he/she jumps, or places a known good component across the suspected
faulty component in the circuit. If the circuit operates correctly with the new
component, the problem is isolated. This is called bridging. Remember,
bridging is generally limited to open components, not shorted components.
Bridging a shorted component might have no effect or it might cause
damage to the new component.
Heat:
Application of heat is used whereby the troubleshooter applies heat to a
suspected “intermittent” component. This thermal intermittent component
breaks down under heat. Heat is usually applied by a hot blower.
Remember,
24
do not use too much heat or damage nearby components.
Freezing:
This technique is used to restore a component temporarily to normal
operation. Freezing technique utilizes cold air from fan or a chemical coolant.
The freezing method cools the suspected thermal intermittent component,
thus temporarily restoring the component to the normal operation.
NOTE
The use of both heat and cold applications can be very useful in identifying
micro circuits board cracks and connections. The heat and cold causes
expansion and contraction, which can temporarily trigger a circuit to operate
allowing the troubleshooter to isolate the problem.
The Signal Tracing / Injection:

This technique is most often used in servicing the radio receivers. A signal is
injected into the malfunctioning receiver to locate the specific inoperable
(dead) stage. A signal is injected into the various points preceding each
stage. A tone will be heard at the speaker it the stage is operating. The
defective stage will not allow the signal to pass through, and the signal will
not
25
be heard at the speaker.
Component Testers, Test Lamps:
These are instruments used to test the quality of the component. These
include megohmmeter, capacitor tester, test lamp, transistor/diode tester,
CRT checker, IC tester, and others.
Resoldring, Adjusting, etc:

These are all techniques used by a troubleshooter on suspected problems.
Because intuition and past experience might indicate that a problem exists.
Bypassing:
This technique is used to locate the suspected problem. Bypassing requires
unplugging one of several circuits. For example, by “shutting off” a transistor,
its effect on the total performance on the circuit can be observed. In other
case a complete circuit board might be disconnected to recheck voltage and
other measurements, as well as observe the effect on the overall operating
system.
In diagnosing electrical / electronic troubles, it is important
that the troubleshooter follow a logical systematic procedure
to eliminate unnecessary time, tests, and replacement of
parts.
Time is money, and good troubleshooter needs a good

“cookbook” approach to troubleshooting. For example most
troubleshooting procedures can greatly aided by use of
diagrams, schematics, and blueprints.
Regardless of the trouble or situation, a good troubleshooter

always records mental or written note of a circuit problem
he/she has repaired and use this information in the future.
REFERENCE
ELECTRONIC TROUBLESHOOTING
By
Tomal & Widmer
1st ED, 1993
Mc Graw.Hill
List of common troubles in electrical machines & equipments
S.No Name of machine Common Troubles

/equipment

Lec # 015 Principles of Troubleshooting

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Principles of Troubleshooting

All electrical equipments are designed to operate safely within

The performance of the equipment is affected if the machine

Troubles can be:

 detected by sight – such as failure of starting of a

Systematic analysis of the reasons for failure of the equipment

To identify major troubles an engineer has to apply his technical

After finding the probable trouble, it is necessary to conduct a

The most serious result of a major un cleared fault is fire which

The most common type of major fault witch is most dangerous

Before attempting to service a device, one must first develop

Therefore servicing a device can be dividing into 3 – phases:

One must proceed in this logical manner; otherwise mistakes, accidents,

This is the 1st step in servicing a device. It involves critical

The first step in problem solving is getting organized.

 Start by obtaining necessary schematics, manufacturer’s

DO NOT SHORT CHANGE THIS STEP BY WASTING A LOT OF TIME

 Describe the problem condition.

Once the actual cause of problem is determined, one is ready to

It is defined as examining various solutions or alternatives and

When deciding what alternative to implement, consider all the

Contingency planning takes into account future changes in the

For example: it might not be wise to replace the motor with a

ALWAYS FOLLOW THE 3 – PHASES

 PROBLEM SOLVING (Troubleshooting)

 DECISION MAKING (Repair)

Follow these basic stages and understanding the

Moisture also causes circuits to draw more current and

Abnormal or excessive movement can lead to breakdowns.

Manufacturing defects are also common. For example loose

Animals and rodents can also be the cause of electrical /

 Device Completely Dead

 Abnormal Amperage Reading

Generally, the short circuit causes the device to

In the grounded circuit, the device often keeps

The Amperage Measurement:

The Resistance Measurement:

The Signal Tracing / Injection:

Resoldring, Adjusting, etc:

Time is money, and good troubleshooter needs a good

Regardless of the trouble or situation, a good troubleshooter

S.No Name of machine Common Troubles

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