Keys for Effective Troubleshooting
- Home >
- articles >
- electrical >
- electrical training
By Warren Rhude
Equipment can malfunction for a variety of reasons. Mechanical contacts and parts can wear out; wires can overheat and burn open or short out; parts can be damaged by impact or abrasion; etc. Equipment may operate in a manner far different than it was designed to, or not at all.
Typically, when equipment fails there is a sense of urgency to get it fixed and working again. If the defective equipment is part of an assembly line, the whole assembly line could be down causing unexpected 'time off' and lost revenue. If you are at a customer site to repair equipment, the customer may watch you, knowing that they are paying for every minute you spend troubleshooting and repairing their equipment. Either one of these scenarios, and there are more, can put a lot of pressure on you to solve the problem quickly.
So What is troubleshooting? It is the process of analyzing the behavior or operation of a faulty circuit to determine what is wrong with the circuit. It then involves identifying the defective component(s) and repairing the circuit.
Depending on the type of equipment, troubleshooting can be a very challenging task. Sometimes problems are easily diagnosed and the problem component easily visible. Other times the symptoms as well as the faulty component can be difficult to diagnose. A defective relay with visual signs of burning should be easy to spot, whereas an intermittent problem caused by a high resistance connection can be much more difficult to find.
What makes an expert Troubleshooter? One trait of expert troubleshooters is that they are able to find virtually any fault in a reasonable amount of time. Easy faults, complicated faults, they find them all. Another trait is that they typically replace only the components that are defective. They seem to have a knack for finding out exactly what is wrong. No trial and error here. So what is their secret?
You might think that a person who has a very good understanding of how the equipment works, should be able to troubleshoot it effectively. Being a good at troubleshooting requires more than this.
Expert troubleshooters have a good understanding of the operation of electrical components that are used in circuits they are familiar with, and even ones they are not. They use a system or approach that allows them to logically and systematically analyze a circuit and determine exactly what is wrong. They also understand and effectively use tools such as prints, diagrams and test instruments to identify defective components. Finally, they have had the opportunity to develop and refine their troubleshooting skills.
If you want to troubleshoot like the pros you will need to develop your skills in each of these areas. Let's look at them in more detail.
Understand How the Circuit Works
Begin by understanding the operation of all components used in the circuit. These may include push buttons, contactors, various types of switches, relays, sensors, motors, and more.
Electrical circuits typically control or operate mechanical systems and components. Therefore, it's essential to understand how these mechanical aspects function to perform the intended work.
You must be able to determine how the circuit operates under normal conditions and assess the impact of changing an input. For example, what happens when a push button is pressed? Which relays energize? Which lights illuminate? Does the pump start or stop? Additionally, you should be able to evaluate how a faulty component might affect circuit behavior.
Use a Logical, Systematic Approach to Analyze Circuit Behavior
This is critical. While troubleshooters may use different methods, all effective approaches share a logical and systematic foundation, minimizing guesswork and trial-and-error. One widely taught method is the 5-Step Approach, summarized below:
1. Observe
Most faults provide clues. Look for visual signs of damage or improper operation. Use all your senses—sounds and smells can be just as revealing. With careful observation and reasoning, many faults can be traced to the actual component with minimal testing.
2. Define the Problem Area
Apply logic and reasoning to your observations to pinpoint the malfunctioning area of the equipment.
3. Identify Possible Causes
Once the problem area is defined, list all potential causes of the malfunction.
4. Determine the Most Probable Cause
Prioritize the list based on likelihood. Focus on the most probable cause first.
5. Test and Repair
Test the suspected component to confirm whether it is the source of the issue. Proceed with repair if necessary.
For more details, see A Systematic Approach to Troubleshooting.
Use Tools Like Prints, Diagrams, and Test Instruments
Start with prints and diagrams. You should be able to determine:
• How the circuit should operate
• What features the circuit includes
• Expected voltages at various points
• Physical location of components
• How components are wired together
Various test instruments are available depending on the circuit type and components. A multimeter is especially valuable—it can measure voltage and resistance, and some models also measure current and capacitance.
Know which instrument to use, when and where to use it, and how to take readings safely.
Practice!
Troubleshooting is a skill that requires practice to master. Depending on your job, opportunities may be limited—and employers may not want you practicing on critical equipment.
One option is to build or purchase training equipment designed to simulate faults. This allows realistic practice without risking operational systems.
Another increasingly popular option is computer simulation. These tools offer realistic scenarios, portability, cost-effectiveness, and safe practice environments. Some even include assessment features that evaluate your troubleshooting skills, provide feedback, and record your process.
Review your own skills in each of these areas. Improving any one of them, along with a good dose of practice, will improve your troubleshooting skills.
About the Author:
Warren Rhude is president of Simutech Multimedia Inc. An e-learning company that develops computer based training simulations for electrical troubleshooting. Warren has an electrical background and has taught troubleshooting for several years at a prominent electrical utility.
Publishers Note:
Simutech Multimedia developed a series of award winning simulations for learning electrical troubleshooting skills. They no longer sell to individuals, but you may want to check if your company or college can afford their great electrical troubleshooting software.
This article is copyright protected by Simutech Multimedia Inc., You are only allowed to link to this page.