CHAPTER 7: ELECTRICAL INSTALLATION BREAKDOWN MAINTENANCE

Unit of learning code ENG/CU/EI/CR/03/4/A

Related Unit of Competency in Occupational Standard: Perform Electrical System
Breakdown Maintenance

7.1 Introduction
This unit describes the competencies required to enable trainee be able to exhibit
competency in the application of health, safety and environmental standards, prepare of
working drawings, assemble tools, equipment, materials and drawing instruments, and
perform electrical installation

7.2 Summary of Learning Outcomes

1 Identify system failure
2 Troubleshoot cause of failure
3 Repair the installation
4 Test the repaired system
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7.2.1 learning outcome 1: Identify System Failure

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7.2.1.1 Introduction
To perform breakdown maintenance successfully, one requires the ability to obtain
information about the failure from the user, refer to manuals for the system and do visual
inspection to identify system failure to identify test points.

7.2.1.2 Information Sheet

Breakdown maintenance
This is a type of maintenance that involves repairing a broken down machine or system
after its continued use until it completely breaks down. For example, this type of
maintenance would occur if you wait until a machine stops working before fixing it. This
is one of several common maintenance types.

Types of Maintenance

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 1. Corrective model: Arising breakdown repair applied to the least critical equipment.
2. Conditional model: The corrective model plus tests to determine the next action
steps, used with equipment that is unlikely to fail.
3. Systematic model: Includes tasks done regardless of the condition of the equipment,
measurements and tests to determine potential issues, and repair of identified faults.
This model is used for equipment that is moderately available and important. These
tasks, however, do not need to be done on a fixed schedule.
4. High-availability model: Used for equipment for which failure would be
catastrophic, including items with above 90 percent of availability and resultant high
production costs and demand. Often, no time can be allotted to stop this machine for
preventive, corrective, or systematic maintenance. For this reason, it requires
predictive maintenance techniques along with an equipment shut down for a complete
overhaul at least once a year. This type of model is commonly used for continuously
rotating equipment, power production turbines, high-temperature furnaces, and
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reaction tanks or reactor deposits.

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Additional Maintenance Considerations

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Maintenance plans must account for both legal regulations about maintenance and
specialized knowledge or resources required to perform the maintenance in question.
Legal maintenance requirements typically apply to equipment that has the potential to
harm people or the environment and outline specific tests, tasks, and inspections that
must be included in the maintenance plan. Examples include:
1. Pressurized equipment and devices
2. High- and medium-voltage installations
3. Lifts
4. Fire prevention facilities and equipment
5. Chemical storage tanks.
Maintenance must be a competent electrician.

Breakdown Maintenance:

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Breakdown maintenance is maintenance performed on a piece of equipment that has
broken down, faulted, or otherwise cannot be operated. The goal of breakdown
maintenance is to fix something that has malfunctioned. To the contrary, preventive
maintenance is performed in order to keep something running.
Sometimes breakdown maintenance is performed because of an unplanned event. For
example, if a critical piece of machinery breaks, the maintenance is performed because of
the imminent need for that machine to operate again. However, breakdown maintenance
can be planned for in advance, which is what we might call “good” breakdown
maintenance.
Breakdown maintenance workflow

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Figure 1 Breakdown maintenance flow chart

There are two types of breakdown maintenance:

1. planned and
2. Unplanned.
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Planned breakdown maintenance
Planned breakdown maintenance means that the organization is prepared for a breakdown
and even expects it to happen. The equipment runs until it breaks, which initiates a run to
failure (RTF) trigger. While RTF triggers can be unplanned, breakdown maintenance
plans use RTF as a way of lowering the cost of maintenance.
This kind of plan needs to be rigorously documented and controlled. Employees should
be clear on exactly which parts will break down and which parts will be maintained
normally via preventive maintenance. Without these checks, a breakdown maintenance
plan can be exploited or run awry.
Unplanned breakdown maintenance
Unplanned breakdown maintenance, on the other hand, occurs when a piece of equipment
fails or breaks unexpectedly—also called an unplanned downtime event. While some
facilities may not utilize a planned breakdown maintenance plan, nearly every facility
needs resources in place for unplanned breakdown maintenance. After all, every piece of
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equipment will break or fault at some point in its life.

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Examples of breakdown maintenance

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Breakdown maintenance is unique in its applications because it cannot be used with

certain industries or products, especially ones that involve health and safety. This means
that breakdown maintenance is most frequently used when parts are inexpensive or
nonessential.
Here are some examples in which breakdown maintenance is applicable:
1. Equipment can’t be repaired at all (inaccessible, designed to not be repaired)
2. Asset consists of inexpensive or easy-to-replace parts
3. Non-critical pieces of equipment (like hand tools)
4. Objects/equipment that are disposable or meant to be replaced at the end of their
lifespan
5. Short-life assets (batteries, high flow pumps)
As you can see from these examples, breakdown maintenance becomes viable when
there’s no inherent safety risk to letting a part or piece of equipment break. As an

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Machine checks
Various instruments are required to perform checks on machines and equipment, either
when the supply is on and they are in operation, or when the supply is off and the
machines are at standstill. Instruments required will include an insulation tester,
continuity tester, doctor tester, feeler gauge, spring balance, and straight edges and string
lines.

Instruments required for supply-off checks

Insulation tester

This is also referred to as a megger. This is an instrument

which produces a d.c. output of 500 V which is sufficient
test voltage for machines operating on supplies up to 650
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V. Tests can be applied to check the insulation values

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between connections, terminal and windings connected to

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different poles, or between these and the exposed

metalwork of the equipment. Circuit diagrams, or electrical knowledge of the plant is
required to ensure that there are no connections which would lead to false values being
obtained. The minimum insulation value should be around 1MΩ, although if the machine
is damp, it may need drying out to obtain this figure
Continuity tester
This is a meter used to check the actual ohmic values of
the windings of a machine, or resistance values of starting
or speed control equipment. Again, detailed knowledge is
required to ensure that there are no parallel paths when the
equipment is fully connected which would lead to false
low values being obtained, or is any alternative circuit is

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connected across (in parallel ) with an open circuit winding.
Ductor tester
This is a device for the measure of very low resistance values which are not practical to
read on the continuity tester that is, small fractions of an ohm, may be 0.01Ω or so. The
tester circulates a heavy current and measures the millivolt (mV) drop across the
resistance path. If a doctor is not available, this form of test can be carried out using a
heavy current supply, such as a car battery and connecting an ammeter in series with a
voltmeter across in parallel with the resistance path to be measured.
𝑉
𝑅= 𝐼
Ω

For example, if on such a test, the current in the circuit is 60A and the millivoltmeter
reads 30 mV, the resistance would be 0.0005 Ω, a very difficult value to read directly on
an ohmmeter. This instrument is used for the measurement of heavy current armature
windings of d.c machines, the copper bars in the rotor of a squirrel-cage motor, or the
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joints and terminations on busbar and heavy-current cable installations.

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Feeler gauges
These are sets of long, parallel blades ranging in thickness
from 0.0254 mm, up to around 0.762mm. They are used
for checking air gaps between the rotor and stator core of
rotating machines, to give an indication of the amount of
wear in the bearings. If the bearings are not worn, the readings will be the same all
around the circumference. If they are worn, the gap at the top will be higher than that at
the bottom. If the difference is large, new bearings will be required to prevent ‘fouling’
between the cores on rotation.
Note: On machines which are almost enclosed, inspection covers at 90o are positioned
on the ‘end covers’ of the motor frame to enable the air gap to be checked.

Spring balance

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This is used to check the tension on contacts and on brush gear of machines and
equipment. The brush is hooked to the balance, gently pulled away from the slip ring or
commutator and the tension value read on the scale. It can then be compared with the
manufacturer’s instructions

Straight edge and string lines

These are used to check horizontal and lateral alignments.

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Instruments required for supply-on checks

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Voltmeter
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This is a meter designed to measure voltages at the supply

and at different points on the switchgear and the machines.
These can be compared with the manufacturer’s data or
against the readings of similar machines

Approved test lamp

This is another method of testing for the presence of supply or voltage although is does
not indicate the actual value.
Test lamps must be of the standard- approved type which contain the necessary safety
current-limited device, such as resistors and fuses, so that in the event of a fault, there

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is no risk of an explosion. They are shrouded with insulation to prevent electric shock
while in use.

Ammeter

This meter is used to check the value of the current in

the supply conductors and in the various circuits of
switchgear and machines, to compare with
manufacturer’s data, nameplate details, etc. Ordinary
ammeter do, of course, need to have the circuit
disconnected and then be connected in series. This is
where the clip-on type ammeter is of advantage.
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When checking current consumption of machines, in some cases the start current may
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be up to eight to ten times the full load value, so be sure of the ammeter range and
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allow the motor to run up to speed.

Multi-test instruments

Current, voltage, insulation and resistance continuity values can

all be measured by one instrument which has all the necessary
scales and ranges. These are selected as required by the use of a
multi-position switch, or a set of outlet sockets. The instrument
contains a battery to provide the current flow to measure
resistance on the continuity range, plus a power-pack to step the
voltage to 500V d.c. for the insulation tests. It is known as the
Electrician’s Universal Meter.

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 Dismantling of standard electrical machines
1. Clean excess dirt, oil, grease, etc from surfaces.
2. Depending on the weight and size of the machine, place it in a suitable position on floor
stand or work bench
3. Any sign of rust on parts to be removed should be sprayed with release fluid
4. Withdraw the key from pinion coupling pulley etc. and then withdraw pinion, etc . See
figure 1 for these operations.
5. Undo nuts from end cover bolts and mark the positions of covers relatives to stator frame.
6. Examine for type of bearings, it may need removal of oil rings on the sleeve type.
7. Remove end covers which will leave ball or roller type bearing on the shaft.
8. Remove rotor or armature from stator. On large machines this may heed lifting gear or two
people, one at each of the shaft.
9. If the motor is fitted with a commutator or slip rings, try to leave these in position on the
shaft. om
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Note ; when the withdrawal screw is fully

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tightened and there is no movement of

coupling, etc. a sharp (shock) blow with
hammer on the screw head will ‘shock it
‘and should produce movement.
Figure 2 Motor coupling pinion or pulley withdrawal tool.

These operations now leave the machine available for cleaning, inspection and maintenance. To
assemble the machine reverse the above steps.

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 Figure 3 Parts of a disassembled motor.

Inspection of machinery and control gear

All electrical machinery and control gear should be inspected and tested at regular intervals.
The frequency of the inspections will depend on the type of equipment and conditions under
which it operates. A record of each inspection, together with test results should be kept for
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future reference.
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The inspection of electrical machinery falls into two categories- mechanical and electrical.
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Mechanical inspection
1. Visibly check the machine for mechanical damage
2. Check the machine for correct alignment to ensure that no undue stresses are imposed to the
bearings
3. Check the air gap (where possible) with feeler gauges.
4. Check the mechanical operation of switchgear and control gear, paying particular attention to
contact condition and pressure
5. If starters are fitted with dash-pots, check the grade and level of the oil
6. In the case of any oil-immersed equipment, check that the oil level is correct and the oil is clean
Electrical inspection
1. Check all connections on machinery and control gear, taking note of the condition of the wiring
2. Carry out protective conductor continuity and insulation resistance tests
3. Check fuses for correct rating and also check that any motor-overload current settings are correct
4. Run machinery, listening for knocks, strange noises, etc, and check that all equipment in the circuit
is functioning correctly
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D.C machines – inspection and maintenance
Owing to their more complex construction, d.c. machines require more frequent maintenance than
the common types of a.c. motors. On d.c. machines, the important points to check are the running
condition, yoke and field windings, brushes, brush holders, brush springs, armature assembly,
bearings, shaft, connection, wiring and insulation.
Running condition
With machine running, check for excessive noise and sparking at the brushes.
Yoke and field windings
With machine isolated from the supply, check that the yoke and field windings are in good
condition
Brushes and brush holders
Check that the brushes and brush holders are in good condition and the brushes move freely in
their holders. Brushes worn to half their original length should be preplaced, and the new brushes
properly bedded in with brush-bedding tape or fine sandpaper.
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Brush springs
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Check that the brush springs are in good condition that spring pressure is adequate and even on all
brushes. A small spring balance may be used for this.
Armature assembly
Check that the coils are in good condition and held securely at the commutator end by their bands.
Check the commutator for concentricity, irregularities and cleanliness. Dirt may be removed with a
commutator brush, and fine sandpaper will remove slight roughness. Emery cloth must not be used
for this purpose as it leaves a greasy film on the commutator. If the commutator is badly worn or
eccentric it must be skimmed on a lathe or on a special skimming machine, after which the
insulation between the segments may have to be cut back.
Bearings
Check bearings as for as possible for condition and correct lubrication.
Shaft
Check the shaft for concentricity and general condition

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Connections and wiring
Check that all connections are tight and that wiring is in good condition with no signs of heat
damage.

D.C machine faults

Symptoms Tests

Starter of the d.c. motor 1. Check that the overload trip is not stuck in the operated position

will not hold in ‘ON and that remote ‘stop’ buttons; etc, are not operated

’position although the 2. Test ‘no-volt coil’ for short or open circuit
3. In the case of series motors, or starter where the no-volt coil is
motor starts correctly
not in series with a shunt winding, check the no-volts coil circuit
for continuity
Excessive sparking at 1. Check brush-gear for correction tension, brushes sticking in
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commutator holders etc

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2. Check polarity of interpoles, if fitted

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3. Test the armature windings for short on open-circuits

D.C generator fails to 1. May be due to loss of residual magnetism; ‘flash’ using a

excite suitable battery

2. Check that the rotation of the armature is in the correct direction
and that field connections have not been reversed.
3. Check field and armature circuits for open or short -circuits

A.C motor faults

Symptoms Tests

Motor completely dead 1. Check the voltage at the isolator and motor terminals

Contactor starter does not 1. Check that overload trips limit trips interlocks and remote

operate although supply at stop buttons are not operated and that the starter controls are

isolator is correct correctly set to the start position

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 2. Test continuity of the contactor coil and its associated circuits
Fuses blow or overload 1. Check that the motor is free to rotate

trips operate when any 2. Check that the starter is being operated correctly

attempts is made to start 3. Test insulation resistance

the motor
Single –phase motor hums 1. Check that the motor is free to rotate (particularly for small

but refuses to start size motors)

2. Test continuity of main and starting windings and of the
centrifugal switch or starting relay
3. Test that the supply is actually reaching the starting winding
via the capacitor, if fitted.

7.2.1.3 Learning activities

Field/Visit to an established electrical workshop
Visit Objective/Aim Indicators Special Instruction
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To establish sources failure ● Failed systems ● Take notes

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● Methods used to identify ● Observe keenly methods

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failures used to identify failed

system

Practical assignment
Visit Objective/Aim Indicators Special Instruction
To acquire skills in system ● Failed systems Participate in the process
failures identification ● Methods used to identify
failures

7.2.1.4 Self - Assessment

1. As an Electrical Installation Technician, what is one rule you should always follow
when working on electric or electronic equipment?
A. Power source
B. Safety first
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 C. Location of equipment
D. Required tools
2. As an Electrical Installation Technician, what should you do to the power supply when working on
an electrical system?
A. Close and tag the circuit breakers and main switches
B. Open and tag the circuit breakers
C. Open and tag the circuit breakers and main switches
D. Open and tag the main switches
3. What is failure of equipment?
4. What are the benefits of maintenance?
5. Which human senses that can be used during an inspection of an installation?
6. Apart from wear and tear, what are three other areas of investigation that you would consider when
carrying out a periodic inspection and test of an installation?
7. Describe breakdown maintenance
8. What are the two categories of machinery inspection?

7.2.1.5 Tools, Equipment, Supplies and Materials

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The following resources are provided

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i. An electrical installation company

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ii. A functional Safety department.

iii. Computers
iv. Stationery
v. Lecture room
vi. Workshop
vii. Projector
viii. Drawing equipment
ix. Workshop
x. Protective clothing

7.2.1.6 References
Donnely. (1980). Electrical Installation theory and practice.
Hyde. (1994). Electrical Installation Principles and practice.
Ngari, c. k. (2019). Electrical installations for artisan level 2. Kenya literature bureau.

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https://electrical-engineering-portal.com/maintenance-management-of-electr

https://www.onupkeep.com/learning/maintenance-types/breakdown-mainten

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restore the circuit to normal operation again. The following are some common installation defects
and omissions which eventually lead to fault;
1. The provision of double-pole fusing on two wire systems with one pole permanently earthed. This
frequently occurs with final circuit distribution boards when the main and/or sub main control
equipment is single-pole and solid neutral.
2. Fuse protection not related to the current rating of cables to be protected, this is very often due to the
equipment manufactures fitting the fuse-carriers with a fuse-element of maximum rating for the
fuse-units in the equipment.to locate the fault
3. Connecting boxes for sheathed- wiring systems placed in inaccessible positions in roof voids and
beneath floors. Indiscriminate bunching of too many cable using screw-on or inadequate connections
4. Insufficient protection provided for sheathed wiring, e.g. to switch positions and on joints in roof voids
5. Incorrect use of materials, not resistant against corrosion, in damp situations(e.g. enameled conduit and
accessories and plain steel fixing screws)
6. Inadequate of complete omission of segregation between cables and/or connections, housed within a
common enclosure, supplying systems for extra low voltage; or telecommunication and power and/or
lighting operating at a voltage in excess of extra-low voltage.
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7. Insufficient attention given in cleaning ends of conduit and/or providing, omission of bushings to
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prevent abrasion of cables at tapped entries, particularly at switch positions.

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8. Insufficient precautions taken against the entry of water to duct and/or trucking systems, particularly
where installed within the floor
9. Incorrect use of PVC insulated and/or a sheathed cables and flexible cords, instead of heat-resistant
type, for connections to immersion heaters, thermal storage block heaters e.t.c.
10. Incorrect use of braided and twisted flexible cord for bathroom pendant fittings and similar situations
subject to damp or condensation.
11. The incorrect use of accessories apparatus or appliances inappropriate for the operating conditions of
the situation in which they are require to function. This often applies to agricultural and farm
institutions.
12. Installation of cable of insufficient capacity to carry the starting current of motors, causing excessive
volt drop.
13. Incorrect rating of fuse element to give protection to the cable supplying this motor.
There are many approaches in trouble shooting Electrical installations. Among them is the
procedure outlined below:
Step 1: Observe

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3 Simple short circuit i. Breakdown in insulation
ii. Poor workmanship
4 Cut or damaged extension i. Mishandling
cord ii. Manufacturers defects
5 Flickering or dimming i. This could be a sign of a poor connection and can lead to
lights eventual arcing
ii. Loose/corroded connections making intermittent contact that
could result in sparking, overheating, and fire.
6 Light bulbs burn out You may have a loose connection in the socket or circuit or worn
frequently out insulation causing overheating.
7 Dead socket outlets i. Dead socket outlets can result from a tripped poor connection
(and possible arcing)
ii. A tripped breaker due to excessive heat buildup resulting in
melted wires or outlets.

Common Faults in an Electric Iron

S/N Fault Probable causes
i. Blown fuse
ii. Broken conductor
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1 Iron does not heat up when connected to iii. Damaged thermostat

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iv. Broken coil

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electrical power
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v. Broken shunt resistor

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2 Sole plate gives shock when touched Loose earth connection

3 Pilot light is OFF but iron operates normally Burnt bulb
4 Iron stuck ON (overheats), no temperature Thermostat stuck ON
control.

Electric Cooker

Figure 5. Circuit Diagram of an Electric Cooker

Electric oven

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 Figure 6. Circuit Diagram of Electric Oven

Common faults in an Electric Cooker and Electric oven

S/N Fault Probable causes
1 Coil does not heat up 1. Burnt/broken coil
2. Faulty thermostat
3. Broken cables
2 Temperature control not possible Thermostat stuck or closed
3 Base plate gives shock Live wire touching base plate and loose/ broken earth
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wire
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Electric Kettle
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An electric kettle has a coil and thermostat as the main components.

Common faults in an Electric Kettle

S/N Fault Probable causes
1 Coil does not heat up 1. Burnt/broken coil
2. Faulty thermostat
3. Broken cables
2 Temperature control not possible Thermostat stuck or closed
3 Kettle gives shock Live wire touching kettle and loose/ broken earth wire

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 Motor operated appliances
Many domestic appliances use electric motors for operation. They include:
1. Hand drill
2. Food mixers
3. Fruit blenders
4. Hair driers
5. Refrigerators
6. Air conditioners
7. Washing machines
8. Air fans
9. Vacuum cleaners
The most common motor used is the A.C. series motor (universal motor). This motor runs on both
AC and DC.

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Figure 7. Circuit diagram of Universal motor

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Common Faults in Electric Motors

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S/N Fault Probable causes

1. Excessive vibration Uneven foundations defective rotor unbalance
1. Excessive load, foreign matter in the air gap or cooling circuit,
2. Frame heating excessive ambient temperature.
2. Partial short circuit in windings
1. Broken wires
3. Motor is dead 2. Blown fuse
3. Field open
4. Brushes disconnected
1. Too much grease.
2. Too little grease
4. Heating of bearings 3. Incorrect assembly.
4. Bearing overloaded
1. Excessive load
5 Brushes heating 2. Brushes not bedding or sticking in holders
3. Incorrect grade of brushes

1. Supply failure (either single phase or complete loss of power)

6. No rotation 2. Inefficient torque
3. Reversed phase

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 1. Running single phase excessive load
7. Steady electrical hum 2. Reversed phase
3. Uneven airgap
8. Mechanical noise 1. Foreign matter in airgap or damaged bearings.
2. Misaligned coupling
9. Pulsating electrical hum 1. Defective rotor
2. Defective wound rotor. Loose connection, partial short circuit e.t.c

Phase Tester
Is used to identify or test a live conductor or the presence or voltage in a circuit

Figure 8. Phase Tester

Ohmmeter
The ohmmeter is used to determine continuity in a circuit. It establishes the whether a conductor is
broken or continuous. The circuit must not have power when continuity is being determined by an
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ohmmeter.
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Insulation Resistance Tester

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Insulation resistance tester is used to measure the resistance between conductors and resistance is
the insulation.
General Procedure for Repair
1. Carry out visual inspection.
The appliance is physically inspected for any breakage or damage or burns. Correct the
defect and test to see if the appliance is in good order.
2. Carry out continuity test and insulation resistance test.
Use a circuit diagram to carry out continuity test. If a fault is detected move to step 3.
3. Dismantle the appliance
As you dismantle mark the parts that go together for easier assembly. Clean the parts and
trace where the fault is occurred by carrying out electrical measurements.
4. Repair the appliance
Once the fault has been identified, replace or repair the faulty component.
5. Assemble the appliance

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 Assemble the appliance to its original form. Follow the reverse process of dismantling.
6. Test the appliance
Carry out the physical tests to ensure the joints are firm and that there are no loose
conductors that can cause short circuit.
Carry out electrical tests to ensure to ensure continuity and good insulation resistance.
Connect the appliance to power to test its working.

7.2.1.5 Learning activities

Field/Visit to an established electrical workshop
Visit Objective/Aim Indicators Special Instruction
To establish techniques used ● Failed systems ● Take notes
in troubleshooting ● Readings ● Observe keenly
techniques used in
om troubleshooting
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Practical assignment
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Visit Objective/Aim Indicators Special Instruction

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To acquire skills in electrical ● Failed systems Participate in the process

equipment troubleshooting ● Instruments

7.2.2.4 Self - Assessment

1. What types of common faults interrupt power through a circuit?
A. Intact wiring, loose terminals, faulty relays, and faulty switches
B. Broken wiring, loose terminals, faulty relays, and faulty switches
C. Broken wiring, tight terminals, faulty relays, and faulty switches
D. Intact wiring, tight terminals, faulty relays, and faulty switches
2. A piece of equipment must be tested after being repaired, what is the purpose of testing it?
A. Ensure technician skills are adequate
B. Ensure future maintenance will not be required
C. Ensure operators can properly operate equipment

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 D. Ensure system works properly
3. An electrical circuit needs to be tested for voltage, how would you connect a digital multimeter to
that circuit?
A. Connect in series
B. Connect in parallel
C. Connect in parallel-series
D. Connect in phase
4. As an Electrical Installation Technician, what test do you perform to find an open circuit?
A. Continuity test
B. Resistance test
C. Voltage check
D. Ohm test
5. As an Electrical Installation Technician, what are the two important things to do when
faced with equipment which is not functioning properly?
6. During troubleshooting of electrical equipment, what are some of the safety tips to be
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observed?
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7. Explain the following terms used in fault diagnosis.

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i. Replacement time
ii. Checkout time
8. Outline the general procedure for repair

7.2.2.5 Tools, Equipment, Supplies and Materials

The following resources are provided
i. An electrical installation company
ii. A functional Safety department.
iii. Computers
iv. Stationery
v. Lecture room
vi. Workshop
vii. Projector
viii. Drawing equipment
ix. Workshop

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 This is a tool used for bending PVC conduits

Stock and die

This is a tool used for making threads on metallic conduits

Side cutter
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This is a tool used for medium and big cables.

Combination Pliers

These are made of metal with insulated handles. They are used for cutting, twisting, bending, holding
and gripping wires and cables

Screw driver

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 It has a cross/flat tip and is used to drive screws with cross/straight slot heads.
Long nose pliers

This is used for cutting and holding wires. It made to reach tight space and or small opening where
other pliers cannot reach. It is also used in making terminal loops of copper wires.
Wire stripper om
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A tool used for removing insulation from insulated cables.

Hacksaw

This is a tool used to cut metal conduit and armoured cable

Measuring tools

To measure wire length and other items, the electrician finds considerable use for measuring
tools such as the extension or zigzag rule, push-pull rule and a steel tape

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Soldering equipment

In doing electric wiring, splices and taps (connections made to wire) should be soldered, unless
you use solderless connectors.
Drilling equipment

Drilling equipment is needed to make holes in building structure passages of conduit sand wires
Ladders
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The term ladder is generally taken to include step ladders and trestles. The use of ladders for
working above ground level is only acceptable for access and work of short duration. It is
advisable to inspect the ladder before climbing it. It should be straight and firm. All rungs and tie
rods should be in position and there should be no cracks in the stiles. The ladder should not be
painted since the paint may be hiding defects. Extension ladders should be erected in the closed
position and extended one section at a time. Each section should overlap by at least the number of
rungs indicated below:
1. Ladder up to 4.8 m length – 2 rungs overlap
2. Ladder up to 6.0 m length – 3 rungs overlap
3. Ladder over 6.0 m length – 4 rungs overlap
Draw wire/Fish tape

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This is a tool used for drawing cables in conduits

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Electrical instrument checking and calibration
A digital Multimeter is used to measure voltage, current and resistance and can be used to
measure electrical continuity in a circuit. There are two types of Multimeter: digital and
analogue. Multimeter should be calibrated or adjusted to a known zero-value prior to use for
accurate readings.

Calibration of Multimeter
Electrical calibration refers to the process of verifying the performance of, or adjusting, any
instrument that measures or tests electrical parameters to maintain their accuracy. Electrical
calibration involves the use of precise devices that evaluate the performance of key properties for
other devices called units under test (UUTs).
Equipment that are not calibrated can result in the wrong decision being made which has the
potential for further damage to what the instrument was to be used for.
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The fragile electronics within Multimeter are protected by a hard casing, which means they can
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usually be stored in a toolbox.

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Multimeter do not require any deep cleaning - just wipe them down with a damp (not wet) cloth,
every now and then. Ensure your devices are fully functioning before each use. Change batteries
and fuses when necessary and consider removing the batteries if the meter will not be used for an
extended period of time.
Many people do a field comparison check of two meters, and call them "calibrated" if they give
the same reading. This isn't calibration. It's simply a field check. It can show you if there's a
problem, but it can't show you which meter is right. If both meters are out of calibration by the
same amount and in the same direction, it won't show you anything. Calibration typically
requires a standard that has at least 10 times the accuracy of the instrument under test.
Calibration, in its purest sense, is the comparison of an instrument to a known standard.
Two instruments, A and B, measure 100 V within 1 %. At 480 V, both are within tolerance. At
100 V input, A reads 99.1 V and B reads 100.9 V. But if you use B as your standard, A will
appear to be out of tolerance. However, if B is accurate to 0.1 %, then the most B will read at 100

32
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 grease. The prongs on the cords should be examined as well. Make sure that the casing
is intact and the prongs are not loose.
c) Oil some electric tools: The electric tools in your toolbox that have a cutting surface
should be lightly oiled to prevent rust. Examine the cutting surface for rust to make sure
that your tools are kept in good condition.
d) Storing your tools: Keep your electric tools stored in their original cases and containers.
This will keep them free of dust and dirt while they are not being used.

7.2.3.3 Learning activities

Field/Visit to an established electrical workshop
Visit Objective/Aim Indicators Special Instruction
To establish tools, equipment i. Tools i. Take notes
and materials preparation ii. Equipment ii. Keenly observe tools
techniques iii. Materials handling
iii. Keenly observe tools
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storage
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Practical assignment
Visit Objective/Aim Indicators Special Instruction
To acquire skills in tools, i. Tools i. Participate in the
equipment and materials ii. Equipment process
preparation techniques iii. Materials ii. Handle tools properly
iii. Store tools properly

4. 7elf - Assessment
1. As an Electrical Installation Technician, what test do you perform to find an open circuit?
A. Resistance test
B. Continuity test
C. Voltage check
D. Ohm test
2.One of the following is the most accurate instrument used for testing insulation resistance,
which one is it?
A. Growler

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 B. Megohmmeter
C. Ohmmeter
D. Tachometer
3. List any four tools used in break down maintenance
4. Describe safe the usage of ladder during maintenance of an electrical system
5. Explain the basic maintenance procedure of electric tools
6. Explain why a multimeter is calibrated
7. Why is calibration required?

7.2.3.5 Tools, Equipment, Supplies and Materials

The following resources are provided
i. An electrical installation company
ii. A functional Safety department.
iii. Computers
iv. Stationery
v. Lecture room
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vi. Workshop
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vii. Projector
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viii. Drawing equipment

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ix. Workshop
x. Protective clothing

7.2.3.6 References
Donnely. (1980). Electrical Installation theory and practice.
Hyde. (1994). Electrical Installation Principles and practice.
ngari, c. k. (2019). electrical installations for artisan level 2. kenya literature bureau.
https://electrical-engineering-portal.com/maintenance-management-of-electr

https://www.onupkeep.com/learning/maintenance-types/breakdown-mainten

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7.2.4 leaning outcome 4: Repair the Installation

7.2.4.1 Introduction

To repair the system successfully, one requires the ability to observe safety precautions are as per
OSHA, repair system in accordance with maintenance manual, use tools and equipment for
repair and record repair activities according to the established procedure.

7.2.4.2 Information Sheet

Remedy of common faults in an installation
S/N Problem Probable cause Action to be taken
1 Loose top plug i. Defects in manufacture Turn off the breaker. Double check for
ii. Overheating inside voltage to the outlet

2 Broken light i. Mechanical blow Turn off the circuit breaker then use a
switch ii. Defects in manufacture flathead screwdriver to remove the
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faceplate. Test the two wires connected

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to the screw for electricity.

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3 Simple short i. Breakdown in Reset the breaker. Repeated

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circuit insulation occurrences with the same appliance

ii. Poor workmanship indicate it’s the appliance – not the
electrical system.
4 Cut or damaged i. Mishandling Unplug both ends. Cut off the old plug.
extension cord ii. Manufacturers defects Gently score and peel back the
insulation jacket, twist them and crew
them into the back of the plug. Then
close the plug and secure the wires.
5 Flickering or i. This could be a sign of a Put off the light and troubleshoot the
dimming lights poor connection and can problem
lead to eventual arcing
ii. Loose/corroded
connections making
intermittent contact that
could result in sparking,
overheating, and fire.

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 iv. This may be due to misalignment of the
drive, excessive end thrust imposed on
4. Heating of motor or too much belt tension. Take
bearings appropriate steps to reduce the load on
bearing.
i. Excessive load i. Reduce load
ii. Brushes not bedding ii. Carefully rebend or clean brushes and
5 Brushes heating or sticking in holders adjust pressure
iii. Incorrect grade of iii. Ensure brushes used are those specified
brushes by the motor manufacturer

i. Supply failure (either i. Disconnect motor immediately with a

single phase or single-phase fault serious overloading
complete loss of and burnout may rapidly occur. Ensure
power) correct supply is restored to motor
ii. Inefficient torque terminals.
6. No rotation
iii. Reversed phase ii. Check starting torque required and
compare with motor rating, taking into
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account type of starter in use. Change to

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larger motor or to different type of

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iii. Check and correct connections in turn

i. Running single phase i. Check if all supply lines are live with
excessive load balanced voltage. Compare line current
ii. Reversed phase with that given on motor name plate.
7. Steady electrical iii. Uneven airgap Reduce load or change to larger motor.
ii. Check and correct connections in turn
hum
iii. Check airgap with feelers. If because of
worn bearings, fit new ones
i. Foreign matter in i. Check airgap, dismantle rotor and clean,
airgap or damaged check with a listening stick. If
bearings. confirmed, try rotating outer face of
8. Mechanical noise ii. Misaligned coupling bearing 180o. If still unsatisfactory fit
new bearing.
ii. Check coupling gap and realign
i. Defective rotor i. Check speed at full load. If it is low and
ii. Defective wound if there is a periodic swing of current
rotor. Loose when running, a defective rotor is
connection, partial indicated and the matter should be
short circuit e.t.c referred to the manufacturer.

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 Remedy of Faults in Fluorescent lamps
Faulty lamp Faulty starter Faulty choke Faulty p.f capacitor Faulty wiring or circuit

Bro M L L C A S I I O E S W O E S W F S C L E C W N
A ken e o i o i h n n p a h r p a h r a h o o a r r o
i elec r w f n r or t c e r o o e r o o u o m o r o o s
r trod c e e t l t- e o n t r n n t r n l r p s t s n u
If trouble is encountered, l e or u m e a e ci r r - h t g c h t g t t o e h s g p
first look below for e lam r i x c a rc n r c f - t i f c c d – n c o e s p
symptoms a p y s p t k ui a e i a c y r a i c i c e o n d u l
k cap d s i s o te l c r u i p c u r a s i n n w w p y
o e i r s r d f t c l r e u l c p c r t n i i p o
r f o e t o su a t u t c o i t u a h c s e r r l r
c i n d u p p u y i u r t i c a u w c i i y f
r c c e pr l p t i t s t i r i r t n n v u
a i k n es t e e t a t g t o i g g o s

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k n o i r w d p n r d g n n t b

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u h i i n s p o - n
b e t n s t h n l
e r f g o o n a
a r l e m
u d c p
l e t u
t r e n
d i
t
s

A lamp does not attempt to x 0 x x x x x x X X X 0

start; no glow from ends
B Lamp flashes on and off x 0 X X X X X x x
C Lamp ends glow steadily 0 0 0 x X x
but lamp does not start

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D Faint glow at one end of x x
lamp
E Lamp lights but is dim X x x
F Lamp takes excessive time x X X x x x x x x
to start
G Premature end-blackening x x x X X X X x
of lamp
H Choke overheats X X X X X x
I Supply fuse blown or lamp X X X X X X x
electrodes fused
J Low power factor X X x
K Excessive radio o x X x
interference
When possible faults has been LAMP STARTER CHOKE CAPACITOR CIRCUIT
located, make these tests to find Check lamp in good circuit and if Check operation of starter in good Check insulation Check, is possible Check circuit against wiring diagram,
which component is faulty proved faulty replace with a new lamp; circuit and if found faulty, fit new resistance, continuity ,insulation resistance examine all connections and terminal.
see note below replacement. and, if possible, and capacitance, Check fuses supply voltage and, if

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impedance. Make sure measure value of possible, insulation resistance of

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tapping and rating are discharge resistor complete fitting.

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correct

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The purpose of this test is to check the phase conductor is taken through the fuse and switch to the
appliance the reason for this test is to ensure that the neutral wire is earthed at the supply
authority’s substation.
The Neutral must never be broken by a fuse or switch.
Preparation for the test
1. Supply OFF
2. Lamps and appliances OUT
3. All switches OFF
4. Neutral links IN
5. Fuses OUT
Instrument used: Ohmmeter or Bell set

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Figure 9 Verification of polarity test

Reading: Zero Ohms on Ohmmeter

NB – This test should not be carried out on a LIVE installation.
Effectiveness of earthing tests
The purpose of this test is:-
i. To measure the resistance of the earth continuity conductor.
ii. To check that the earth continuity heavy leakage currents.
iii. To ensure that the earth electrode is effectively connected to the general mass of earth.

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Earth Continuity
Earth continuity is making sure that should there be an electrical fault, all exposed metalwork in a
building is bonded together and connected to the earth block in the consumer unit, leaking the
current to earth and automatically disconnecting the supply. An earth continuity test will verify
that exposed metalwork in a building is bonded together and connected to the earthing block in the
consumer unit.
The ohmmeter leads are connected between the points being tested, between simultaneously
accessible conductive parts e.g. pipe works, sinks etc. This test will verify that the conductor is
sound.

Earth fault loop test

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Figure 10 Earth fault loop test

The earth fault loop is the path which the leakage current will take back to the supply transformer
when there is an earth leakage in an installation. The path is as shown below.
The test must be carried out on a new or largely modified installations where earth-leakage
protection relies on the operation of fuses or excess current circuit – breakers.
1. The leakage current flows from the faulty conductor into the earth continuity conductor.
2. It then flows along the earth continuity conductor to the earthing lead.
3. The earthing lead carries the current to the earth electrode.

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 4. The leakage current now takes the shortest path back to the earthed neutral of the supply
transformer.
The purpose of this test is to show that the earth fault loop is capable of carrying heavy leakage
currents so that the protective gear (e.g. fuses) will operate when leakages occur between the line
conductor and the earthed metalwork of the installation.
Apparatus: Line-earth loop tester (Megger).

Method
The Line-earth loop tester, operating on fall mains voltage, passes a short duration current of
approximately 20A from the line conductor, through the consumer’s earth continuity conductor
and the earth return path to the neutral of the supply transformer. This instrument measures the
value of the loop in Ohms.
Readings
The minimum permissible reading depends on the operating conditions but the two main factors
are:-
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Operating current of fuse or circuit breaker protecting circuit.

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Supply voltage.
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Example
If the circuit fuse operated at 50A and the supply voltage is 240V then the resistance of the earth
240 𝑉
fault loop must not be more than 60 𝐴
= 4Ω . If the resistance is higher than this value the

fuse will not open under serious fault conditions.

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 Figure 11 Circuit of megger line-earth loop tester

Factors determining resistance of earth fault loop are as follows.

1. The continuity of the metallic circuit up to the earth electrode (the earth continuity conductor and the
earthing lead).
2. The resistance of the body of earth surrounding the earth electrode.
Earthing Lead – The minimum size of copper earthing lead is 1mm2. The earthing lead
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connecting an earth–leakage circuit-breaker to an earth electrode need not exceed 2.5mm2. The
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earthing lead should be protected against mechanical damage and corrosion and the clamp used for
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connecting the earth lead to the earth electrode should be non-ferrous and should be accessible for
inspection.
The resistance area is the name given to the resistance of the body of earth surrounding the earth
electrode.
The resistance area is measured using
1. An alternating current (at a maximum pressure of 40V) is connected between the main earth
electrode A and an auxiliary electrode B, placed about 30m from A. An ammeter is placed in series
with the supply to measure the current through the circuit.
2. A second auxiliary electrode C is placed between A and B and the voltage (potential difference) is
measured between A and C. the resistance of the resistance area is found by taking various
readings from point A towards point B. Outside the resistance area the resistance is constant .

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Figure 12 Resistance area measurement

𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝐴 𝑎𝑛𝑑 𝐶

𝑅= 𝐶𝑢𝑟𝑟𝑒𝑛𝑡

Insulation Tests
The purpose of the insulation resistance test is to make sure that there is no possibility of leakage
currents flowing between insulated conductors and also to make sure that there is no leakage of
current between the conductors of the installation and ‘the general mass of earth.
Earth Insulation Resistance Test

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 Figure 13 Insulation resistance test.

If the reading obtained is less than the minimum allowed, then the installation must be sub-divided
to isolate the faulty circuit.
Between Poles Test
The purpose of the between poles test is to make sure that there are no short circuit or
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low-resistance connections between the ‘live’ conductors in the installation.

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Preparations for Test

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1. Supply OFF
2. Lamps OUT; appliances OFF
3. All switches ON; all fuses and neutral links IN

Test Instrument
Insulation resistance tester (e.g. megger). The test should be carried out at the nearest possible
point to the supply Authority’s equipment.
Method
Connect insulation resistance tester between phase and neutral
Readings
The minimum readings required are similar to those for the earth insulation resistance test on the
same installation.
Test of Ring Circuit Continuity

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On completion of a ring circuit installation a test, similar to that carried out to check the
verification of polarity, must be carried out to ensure the continuity of all time, neutral and earth
continuity conductors throughout the ring circuit. This test is carried at the point of connection in
the distribution fuse board prior to the completion and connection of the ring circuit conductors.
Tests to be carried out are given below
1. Verification of polarity – Used to check that phase wire is switched and fused. Reading on
ohmmeter or bell set-zero or continuity.
2. Earthing tests – To ensure that the metalwork of the installation is ‘effectively connected to the
general mass of earth’.
(a). testing earth continuity conductor. Maximum reading, 0.5 Ω.
(b). Testing earth fault loop impedance by current injection. Reading determined by setting of
protective equipment.
(c). testing effectiveness of earth electrode. Reading determined by setting of protective equipment.
3. Insulation tests (a) between poles (b). Earth insulation resistance (between all conductors and earth).
4. Ring circuit should be tested with ohmmeter or bell set for continuity of ring.
Commissioning
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After completion of the installation, it is the duty of the contractor to now hand over the completed
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building to the owner. This is achieved by filling in details of the installation on completion
certificate and handing it over to owner and a copy to the supply authority.

Completion Certificate.

Upon completion of new installation or a major extension on existing installation and inspection
and testing has been carried out. The contractor the contractor should issue out a completion
certificate. The certificate gives details of the installation including the name and address of the
customer number of appliances, method of earthing and readings of the tests carried out. The
certificate states that the installation has been carried out in accordance with the I.E.E regulations
and also recommends periodic inspection and testing.

Inspection Certificate.

After an installation has been re-inspected and tested as recommended in the completion certificate
on specified date an inspection certificate is completed and handed on to the consumer. The

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certificate contains more details than the completion certificate since it gives full range of tests of
the installation

7.2.5.3 Learning activities

Field/Visit to an established electrical workshop
Visit Objective/Aim Indicators Special Instruction
To establish techniques used ● Instruments ● Take notes
in testing an installation ● Readings ● Note instruments used
● Note measurement
values.

Practical assignment
Visit Objective/Aim Indicators Special Instruction
To acquire skills in testing an ● Instruments Participate in the process
electrical installation ● Readings

7.2.5.4 Self -Assessment

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1. The picture below shows one of the instruments used by electrical artisans in their daily activities,
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What is the name of the instrument?

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A. Tester
B. Earth loop tester
C. Multimeter
D. Voltmeter

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 2. What is the test voltage used when performing an insulation resistance test on a 230V
system?
A. 50V
B. 500V
C. 24V
D. 250V
3. Who is supposed to carry out periodic testing on an existing installation?
A. Energy regulatory commission.
B. Competent Person
C. Kenya power
D. Building inspector
4. What is the purpose of testing a repaired Installation?
5. What are the main tests to be carried out on a complete electrical installation
6. With the aid of a diagram describe verification of polarity test
7. Describe what is an inspection certificate
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7.2.5.5 Tools, Equipment, Supplies and Materials

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The following resources are provided

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i. An electrical installation company

ii. A functional Safety department.
iii. Computers
iv. Stationery
v. Lecture room
vi. Workshop
vii. Projector
viii. Drawing equipment
ix. Workshop
x. Protective clothing

7.2.5.6 References
Donnely. (1980). Electrical Installation theory and practice.
Hyde. (1994). Electrical Installation Principles and practice.
ngari, c. k. (2019). electrical installations for artisan level 2. kenya literature bureau.
https://electrical-engineering-portal.com/maintenance-management-of-electr

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 ● Wear all required personal protective equipment. In the event of equipment failure or
accident contact, your personal protective equipment may save your life.
7. Explain the following terms used in fault diagnosis.
Replacement time - this involves removal of the faulty, followed by connection and wiring,
as appropriate of a replacement.
Checkout time - this involves verifying that the fault condition no longer exists and that the
system is operational.
8. Outline the general procedure for repair
i. Carry out visual inspection.
ii. Carry out continuity test and insulation resistance test.
iii. Dismantle the appliance
iv. Repair the appliance
v. Assemble the appliance
vi. Test the appliance
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7.2.6.3 Prepare list of tools, Equipment & Materials

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1. B
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2.B
3. List any four tools used in break down maintenance
i. Ladder
ii. Hammer
iii. Pliers
iv. Screw drivers e.t.c
4. Describe safe the usage of ladder during maintenance of an electrical system
The term ladder is generally taken to include step ladders and trestles. The use of ladders for
working above ground level is only acceptable for access and work of short duration. It is
advisable to inspect the ladder before climbing it. It should be straight and firm. All rungs
and tie rods should be in position and there should be no cracks in the stiles. The ladder
should not be painted since the paint may be hiding defects. Extension ladders should be
erected in the closed position and extended one section at a time. Each section should
overlap by at least the number of rungs indicated below:
1. Ladder up to 4.8 m length – 2 rungs overlap
2. Ladder up to 6.0 m length – 3 rungs overlap

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 3. Ladder over 6.0 m length – 4 rungs overlap

5. Explain the basic maintenance procedure of electric tools

To ensure that your electric tools work properly, you must take proper care of them. A good
regimen of maintenance for your tools is one thing that you can do to make sure that the tool
you need is working when you need it.
a) Clean out the dust: To make sure that your electric tools are ready for use, keep them
clean and free of dust. The housing intake on your electric tools and the exhaust are
especially important areas to keep clean. Take some time to clean out the dust every
once in a while on your tools while they are sitting in storage.
b) Check the cords: Look for wear and tear on the power cords on your electric tools.
There can be damage to the insulation and you should keep an eye out for loose wires.
This will ensure that your electric tool can get the power that it needs to function
without an accident. Wipe the cords down to keep them from becoming damaged from
oil and grease. The prongs on the cords should be examined as well. Make sure that the
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casing is intact and the prongs are not loose.

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c) Oil some electric tools: The electric tools in your toolbox that have a cutting surface
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should be lightly oiled to prevent rust. Examine the cutting surface for rust to make sure
that your tools are kept in good condition.
d) Storing your tools: Keep your electric tools stored in their original cases and
containers. This will keep them free of dust and dirt while they are not being used.
6. Why Multimeter is calibrated
A digital Multimeter is one of the most commonly used pieces of test and measurement
instrumentation. Quality processes depend on its continual proper operation. However, time,
environment, and physical use (or abuses) change a digital multimeter’s characteristics. That’s why
it’s important to periodically calibrate or verify the performance of a digital multimeter. A
multimeter should be calibrated or adjusted to a known zero-value prior to use for accurate
readings.
7. Why is calibration required?
Calibration may be required for the following reasons:
a) a new instrument

49
 b) after an instrument has been repaired or modified
c) when a specified time period has elapsed
d) when a specified usage (operating hours) has elapsed
e) before and/or after a critical measurement
f) after an event, for example:
iii. after an instrument has been exposed to a shock, vibration, or physical damage,
which might potentially have compromised the integrity of its calibration
iv. sudden changes in weather
g) whenever observations appear questionable or instrument indications do not match
the output of surrogate instruments
h) As specified by a requirement, e.g., customer specification, instrument manufacturer
recommendation.

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7.2.6.4 Repair the Installation

1. A
2. A
3. B
4. D
5. State possible cause and remedy for the following faults in an electrical installation
(a) Dead socket outlets
(b) Flickering or dimming lights
(c) Light bulbs burn out frequently
(a) Dead socket outlets can result from a tripped poor connection (and possible arcing), a tripped
breaker due to excessive heat buildup resulting in melted wires or outlets. Replace the damaged
socket outlet, carry out rewiring if the cables are damaged
(b) This could be a sign of a poor connection and can lead to eventual arcing
Loose/corroded connections making intermittent contact that could result in sparking,
overheating, and fire. Put off the light and fix these problems

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 (c) You may have a loose connection in the socket or circuit or worn out insulation causing
overheating. Open the lamp holder and identify the problem then fix it.

7.2.6.5 Test the Repaired System

1. C
2. B
3. B
4. What is the purpose of testing a repaired Installation?
The reason for testing an installation is to detect faults before dangerous situations arise.
Factors which the installation must be protected against are:-
i. Earth leakage and danger of electric shock
ii. Excess current
iii. Moisture and corrosion
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5. What are the main tests to be carried out on a complete electrical installation?
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1. Verification of polarity test

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2. Effectiveness of earthing test

3. Ring circuit continuity test
4. Insulation resistance test
5. Earth fault loop impedance test
6. With the aid of a diagram describe verification of polarity test
The purpose of this test is to check the phase conductor is taken through the fuse and switch to
the appliance the reason for this test is to ensure that the neutral wire is earthed at the supply
authority’s substation.
The Neutral must never be broken by a fuse or switch.
Preparation for the test
1. Supply OFF
2. Lamps and appliances OUT

2
 3. All switches OFF
4. Neutral links IN
5. Fuses OUT
Instrument used: Ohmmeter or Bell set
7. Describe what an inspection certificate is.
After an installation has been re-inspected and tested as recommended in the completion
certificate on specified date an inspection certificate is completed and handed on to the
consumer. The certificate contains more details than the completion certificate since it gives
full range of tests of the installation

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Reading: Zero Ohms on Ohmmeter

This test should not be carried out on a LIVE installation.