TROUBLESHOOTING AND FAULT ANAYSIS

…Developing the Nation’s Human Resource

 What we will learn…….
• Definition of Troubleshooting
• Introduction to Steps in Electrical/Electronic troubleshooting.
• The Five (5) Steps to Troubleshooting
• Follow- up.
• Summary.

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 INTRODUCTION
Trouble shooting is a form of problem solving most often applied to
repair of failed products or processes. It is
• Logical
• Systematic
Search for the source of a problem so that it can be solved.
Trouble shooting is used in many fields such as
learning.
I. System administration
II. Electronics
III. Automotive repair.

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 INTRODUCTION……….

Fault analysis on the other hand is the systematic

examination of faults, errors, or malfunctions within a system
or process to identify their root causes and develop
strategies for resolution. It involves in-depth investigation
and diagnostic procedures to pinpoint the underlying issues
affecting system reliability and functionality.

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 INTRODUCTION……….

Fault detection is also a critical aspect of maintenance in

various industries, ensuring the safety, reliability, and efficiency
of equipment and systems. To effectively identify and address
faults in machinery, electrical systems, and infrastructure,
professionals rely on a range of specialized tools and
equipment designed for diagnostic purposes.

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 INTRODUCTION……….

Fault detection is the process of identifying abnormalities,

malfunctions, or deviations from normal operating conditions
in machinery, electrical systems, equipment, or infrastructure.
The goal of fault detection is to detect potential defects,
failures, or performance issues early on, before they escalate
into critical failures that could lead to downtime, safety
hazards, or reduced efficiency

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 What is Troubleshooting?

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 WHAT IS TROUBLESHOOTING……….

.
Troubleshooting can be described as a logical system of investigation
designed to yield the correct cause of breakdown in the shortest possible
time and with least likelihood of error.

The term breakdown is used to indicate any machine or equipment

condition that is considered to be less than satisfactory according to
these factors.

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 WHAT IS TROUBLESHOOTING……….

Troubleshooting is also the systematic

search for the source of a problem so that
it can be solved.

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 The Five (5) Steps to Electrical/Electronic
Troubleshooting.

The approach described here is a logical, systematic approach

called the 5 Step Troubleshooting Approach. It is a proven
process that is highly effective and reliable in helping to solve
electrical problems.
In fact, the principles covered in this approach can be applied to
many other types of problem solving scenarios, not just electrical
circuits.

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 The 5 Steps Troubleshooting Approach consists of the following:

Preparation…
Step 1 Observation
Step 2 Define Problem Area
Step 3 Identify Possible Causes
Step 4 Determine Most Probable Cause
Step 5 Test and Repair

Let’s take a look at these in more detail.

Before you begin to troubleshoot any piece of equipment,
you must be familiar with your organization’s safety rules
and procedures for working on electrical equipment.

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 These rules and procedures govern the methods you can
use to troubleshoot electrical equipment (including your
lockout/tagout procedures, testing procedures etc.) and
must be followed while troubleshooting.

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 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. You should also
have on-hand any documentation describing the problem.
(i.e., a work order, trouble report, or even your notes taken
from a discussion with a customer.)

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 Step 1 – Observe
Before grabbing your ohmmeter, there are several areas which you can check
out merely by observing the panel:
1. Push alarm silence button ( to save your ears).
2. What alarm lights are on? ( Do not reset until you determine the cause of
alarm).
3. Are pump “run” lights on?
4. Is pump “overload/BT” light on?
5. Are both D.C. and A.C. power lights on?
6. Has someone diddled with the switches?
7. Are relays energized which should be, and those not which should not be?
(Many relays have Red lights on the socket when energized).
8. Is overheating evident? ( Smoke, smell, discolored wiring).

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 Step 2 – Define Problem Area

It is at this stage that you apply logic and reasoning to your

observations to determine the problem area of the malfunctioning
equipment. Often times when equipment malfunctions, certain
parts of the equipment will work properly while others not.
The key is to use your observations (from step 1) to rule out parts
of the equipment or circuitry that are operating properly and not
contributing to the cause of the malfunction. You should continue
to do this until you are left with only the part(s) that if faulty, could
cause the symptoms that the equipment is experiencing.

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 To help you define the problem area you should have a
schematic diagram of the circuit in addition to your noted
observations.
Starting with the whole circuit as the problem area, take each
noted observation and ask yourself “what does this tell me
about the circuit operation?" If an observation indicates that a
section of the circuit appears to be operating properly, you can
then eliminate it from the problem area. As you eliminate each
part of the circuit from the problem area, make sure to identify
them on your schematic. This will help you keep track of all
your information.

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 Step 3 – Identify Possible Causes

Once the problem area(s) have been defined, it is necessary to

identify all the possible causes of the malfunction. This typically
involves every component in the problem area(s).
It is necessary to list (actually write down) every fault which
could cause the problem no matter how remote the possibility
of it occurring. Use your initial observations to help you do this.
During the next step you will eliminate those which are not
likely to happen.

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 Step 4 – Determine Most Probable Cause

Once the list of possible causes has been made, it is then

necessary to prioritize each item as to the probability of it
being the cause of the malfunction. The following are some
rules of thumb when prioritizing possible causes.
Although it could be possible for two components to fail at the
same time, it is not very likely. Start by looking for one faulty
component as the culprit.

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 The following list shows the order in which you should
check components based on the probability of them
being defective:
 First look for components which burn out or have a tendency
to wear out, i.e. mechanical switches, fuses, relay contacts,
or light bulbs. (Remember, that in the case of fuses, they burn
out for a reason. You should find out why before replacing
them.)
 The next most likely cause of failure is coils, motors,
transformers and other devices with windings. These usually
generate heat and, with time, can malfunction.

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  Connections should be your third choice, especially screw type or
bolted type. Over time these can loosen and cause a high
resistance. In some cases this resistance will cause overheating
and eventually will burn open. Connections on equipment that is
subject to vibration are especially prone to coming loose.
 Finally, you should look for is defective wiring. Pay particular
attention to areas where the wire insulation could be damaged
causing short circuits. Don't rule out incorrect wiring, especially
on a new piece of equipment.

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 Step 5 – Test and Repair
Testing electrical equipment can be hazardous. The electrical
energy contained in many circuits can be enough to injure or kill.
Make sure you follow all your companies’ safety precautions,
rules and procedures while troubleshooting.
Once you have determined the most probable cause, you must
either prove it to be the problem or rule it out. This can sometimes
be done by careful inspection however, in many cases the fault
will be such that you cannot identify the problem component by
observation and analysis alone. In these circumstances, test
instruments can be used to help narrow the problem area and
identify the problem component.

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 There are many types of test instruments used for troubleshooting.
Some are specialized instruments designed to measure various
behaviors of specific equipment, while others like the multimeters
are more general in nature and can be used on most electrical
equipment. A typical multimeter can measure AC and DC Voltages,
Resistance, and Current.

A very important rule when taking meter readings is to predict what

the meter will read before taking the reading. Use the circuit
schematic to determine what the meter will read if the circuit is
operating normally. If the reading is anything other than your
predicted value, you know that this part of the circuit is being
affected by the fault.

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 After replacing the component, you must test operate all
features of the circuit to be sure you have replaced the
proper component and that there are no other faults in the
circuit. It can be very embarrassing to tell the customer
that you have repaired the problem only to have him find
another problem with the equipment just after you leave.

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 REPLACEMENT OR REPAIR:

The decision of whether to replace or repair a faulty component

may depend on the overall maintenance policy of the
organization. If a component is repaired then it should be tested.
If possible, before it is reinstalled.

If failure was identified as being due to either misuse or inherent

weakness then the repair made must include steps to avoid
changes or modifications to other parts of the machine, or system
or may involve the selection of different materials.

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 Follow up
Although this is not an official step of the troubleshooting
process it nevertheless should be done once the equipment has
been repaired and put back in service. You should try to
determine the reason for the malfunction.
 Did the component fail due to age?
 Did the environment the equipment operates in cause
excessive corrosion?
 Are there wear points that caused the wiring to short
out?
 Did it fail due to improper use?
 Is there a design flaw that causes the same component
to fail repeatedly?

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 Through this process further failures can be minimized.
many organizations have their own follow-up
documentation and processes. Make sure you check your
organization’s procedures.

Adopting a logical and systematic approach such as the 5

Step Troubleshooting Approach can help you to
troubleshoot like an expert!

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 Summary
By following a well thought-out systematic process when
challenged with an electrical troubleshooting problem, you will
greatly enhance your effectiveness. Invest a little time up front
doing your research and determining your troubleshooting pan of
action. A benefit of newer test equipment packages which
combine multiple testing technologies in one unit is how much
they increase the flexibility and capability of a technician’s
troubleshooting toolbox.
Inventory your test equipment and determine what you have
available when the opportunity to use the five step
troubleshooting process presents itself.

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 QUESTIONS

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 THANK YOU

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