BUILDING ELECTRICAL

INSTALLATION LEVEL-III
Based on October 2032, Curriculum Version II

Module Title: - low voltage electrical apparatus and

circuits Trouble-shooting

Module code: EIS BEI3 M7 1023

Nominal duration: 80Hour

Prepared by: Ministry of Laboure and Skill

October, 2023
Addis Ababa, Ethiopia
Contents

Acknowledgment............................................................................................................................. 4
Acronym .......................................................................................................................................... 4
Introduction to the Module .............................................................................................................. 5
UNIT ONE: DIAGNOSE FAULTS................................................................................................ 7
1.1. Basic concept of trouble-shoot faults .............................................................. 8
1.2. Extent and nature of the electrical installation ................................................. 9
1.3. OHS procedures & risk control measures ..................................................... 10
1.4. Tools, Equipment and materials .................................................................... 11
1.5. Identification of faults .................................................................................... 11
1.6. Faults symptoms and their cause.................................................................. 20
1.7. Visual fault/breakdown inspection ................................................................. 21
Self-check #1 ................................................................................................................................. 24
UNIT TWO: TROUBLE-SHOOTING AND REPAIRING FAULTS ........................................ 25
2.1. Circuits, Machines and plants ....................................................................... 25
2.2. Equipment and associated ............................................................................ 40
2.3. Circuit Testing procedure of Trouble-shooting ............................................... 45
2.4. Methods and technique of trouble-shooting ................................................... 46
2.5. Circuit and wiring diagrams ........................................................................... 48
2.6. Critical aspects of trouble-shooting ................................................................ 52
I Self-check-2 ................................................................................................................................ 53
Operation sheet 1. Steps how to Troubleshooting Electrical apparatus ........................................ 55
Operation sheet 2 Steps how to find Electrical apparatus fault ..................................................... 56
Lap test .......................................................................................................................................... 57
UNIT THREE: COMPLETION AND REPORT TROUBLE-SHOOT AND REPAIR
ACTIVITIES ................................................................................................................................. 58
3.1. justification for repairs to apparatus ............................................................... 58
3.2 Documentation and reporting ......................................................................... 60
3.3. Clean and a safe work area ........................................................................... 61
Self-check 3 ................................................................................................................................... 64
Reference Materials ....................................................................................................................... 65
Developer‟s Profile........................................................................................................................ 66

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Acknowledgment

Ministry of Labor and Skills wish to extend thanks and appreciation to the many
representatives of TVET instructors and respective industry experts who donated their time
and expertise to the development of this Teaching, Training and Learning Materials (TTLM).

Acronym

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 OHS - -------------------------------- Occupational Health & Safety
OSHA- ------------------------------- Occupational Health and Safety
Administration
PPEs – ------------------------------- Personal Protective Equipment
GFCI- ------------------------------- Ground Fault Current Interrupt
RD - --------------------------------- Requirements Document
DC – --------------------------------- Direct Current
AC – --------------------------------- Alternative Current
DMM- ------------------------------- digital multimeter
ELV – ------------------------------- extra low voltage

CB- ---------------------------------- circuit breaker

LLL- --------------------------------- line to line to line

LLLG- ------------------------------- line to line to line to ground

SOPs- ------------------------------------- standard operating procedures

Introduction to the Module

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In Building Electrical installation filed low voltage electrical apparatus and circuits Trouble-
shooting is very important for rectify faults and repair faults and report trouble-shoot It helps
to know the Basic concept of trouble-shoot faults, Understand Trouble-shooting and repairing
faults and report trouble-shoot and repair activities
This module is designed to meet the industry requirement under the Building Electrical
Installation occupational standard, particularly for the unit of competency: low voltage
electrical apparatus and circuits Trouble-shooting
This module covers the units:
 Diagnose faults
 Trouble-shoot and repair faults.
 Completion and report trouble-shoot and repair activities
Learning Objective of the Module
 Identify Diagnose faults
 Understand Trouble-shooting and repairing faults
 Complete and report trouble-shoot and repair activities
Module Instruction
For effective use this module trainees are expected to follow the following module instruction:
1. Read the information written in each unit
2. Accomplish the Self-checks at the end of each unit
3. Perform Operation Sheets which were provided at the end of units
4. Do the “LAP test” giver at the end of each unit.
5. Read the identified reference book & website.

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UNIT ONE: DIAGNOSE FAULTS

This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 Basic concept of trouble-shoot faults
 Extent and nature of electrical installation
 OHS procedures & risk control measures
 Tools, Equipment and materials
 Identification of faults
 Faults symptoms and their causes
 Visual fault/breakdown inspection
Visual fault/breakdown inspectionThis unit will also assist you to attain the learning outcomes
stated in the coverage. Specifically, upon completion of this learning guide, you will be able to:
 Understanding of basic concept of trouble-shoot faults
 Inspect the Extent and nature of electrical installation
 Follow OHS procedures & risk control measures
 Identify tools, Equipment and materials
 Describe the Identification of faults
 Explain the Faults symptoms and their cause
 Visual fault/breakdown inspection

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1.1. Basic concept of trouble-shoot faults

Troubleshooting faults is the process of identifying and resolving the cause of a problem. It is
a systematic approach to solving problems by breaking them down into smaller, more
manageable parts.
Identify the problem. What is the specific problem that is occurring?
Gather information. What information is available about the problem? This may include
information about the equipment involved, the environment, and the people who are using it.
Generate hypotheses. What are the possible causes of the problem?
Test the hypotheses. Test each hypothesis to determine if it is the cause of the problem.
Implement a solution. Once the cause of the problem has been identified, implement a
solution to resolve it Verify the solution. Test the solution to ensure that it has resolved the
problem. Troubleshooting faults can be a challenging task, but it is an essential skill for
anyone who works with equipment or systems. By following the basic troubleshooting
process, you can quickly and efficiently identify and resolve problems.
Document your steps. This will help you to keep track of what you have done and to avoid
making the same mistakes again.
Ask for help. If you are stuck, don't be afraid to ask for help from a colleague or supervisor.
There are many different troubleshooting techniques that can be used, depending on
the specific problem that is occurring. Some common troubleshooting techniques
include:
Visual inspection: Look for any obvious problems with the equipment or system.
Functional testing: Test the equipment or system to see if it is working properly.
Log analysis: Review the system logs to look for any errors or warnings.
Diagnostics: Run diagnostic tests on the equipment or system to identify any problems.

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1.2. Extent and nature of the electrical installation

The extent and nature of an electrical installation is determined from job specifications. These
specifications typically include the following information:

The size and type of building: Larger buildings with more complex electrical needs will
require more extensive electrical installations.
The number and type of appliances and equipment: The number and type of appliances
and equipment that will be used in the building will determine the size and capacity of the
electrical system that is needed.
The specific requirements of any specialized equipment: Some specialized equipment,
such as medical equipment or industrial machinery, may have specific electrical requirements
that need to be met.
Any local codes or regulations: There may be local codes or regulations that govern the
installation of electrical systems. It is important to check with your local authorities to ensure
that your installation complies with all applicable codes and regulations.
Once you have this information, you can begin to develop a plan for your electrical
installation. This plan should include the following:
A diagram of the electrical layout: This diagram should show the location of all electrical
outlets, switches, and fixtures.
A list of all electrical components: This list should include the type, size, and quantity of all
electrical components that will be used in the installation.
A schedule for the installation: This schedule should include start and end dates for each
phase of the installation.
Once you have developed a plan, you can begin to install the electrical system. It is important
to follow the manufacturer's instructions for each electrical component and to comply with all
applicable codes and regulations.
Here are some additional tips for determining the extent and nature of an electrical installation
from job specifications:
Consider future needs: When planning your electrical installation, it is important to consider
future needs. For example, if you are planning to add on to your home in the future, you will
want to make sure that your electrical system is sized to accommodate the additional load.

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Be energy efficient: When choosing electrical components, be sure to select energy-efficient
options. This will help you to save money on your energy bills in the long run.
1.3. OHS procedures & risk control measures

OHS procedures and risk control measures are designed to protect employees from hazards in
the workplace. These procedures and measures should be implemented in a hierarchy of
controls, with the most effective controls at the top and the least effective controls at the
bottom.
Examples of OHS procedures and risk control measures:

Elimination: Removing a trip hazard from a walkway.

Substitution: Using a less hazardous chemical than before.

Engineering controls: Installing guards on machinery.

Administrative controls: Developing and implementing safe work procedures.

PPE: Providing employees with safety glasses, gloves, and hard hats.

It is important to note that the hierarchy of controls is not a rigid set of rules. The best way to
control
a hazard will depend on the specific situation. For example, it may not be possible to
eliminate a hazard, so the next best option may be to substitute it with a less hazardous one.

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1.4. Tools, Equipment and materials

The tools, equipment, and materials that you need for troubleshooting faults will vary
depending on the specific problem that you are trying to solve. However, some common tools
and equipment that can be used for troubleshooting faults include:
Multimeter: A multimeter is a versatile tool that can be used to measure voltage, current, and
resistance.
Logic probe: A logic probe is a tool that can be used to test the state of digital signals.
Cable tester: A cable tester is a tool that can be used to test the integrity of cables.
Voltage detector: A voltage detector is a tool that can be used to detect the presence of
voltage.
Hand tools: A variety of hand tools, such as screwdrivers, wrenches, and pliers, may be
needed to disassemble and reassemble equipment.
Replacement parts: It is a good idea to have a supply of replacement parts on hand, so that
you can quickly replace any faulty parts that you find.
Cleaning supplies: cleaning supplies, such as alcohol and contact cleaner, can be used to
clean electrical components.

1.5. Identification of faults

There are a number of ways to identify faults in electrical equipment. Some common methods
include:
Visual inspection: Look for any obvious signs of damage, such as burned wires, loose
connections,
Functional testing: Test the equipment to see if it is working properly. For example, if you
are troubleshooting a light switch, you would turn on the switch to see if the light comes on.
Log analysis: Review the equipment logs to look for any errors or warnings. For example, if
you are troubleshooting a server, you would review the event logs to look for any errors that
may be causing the server to crash.
An electrical fault is the deviation of voltages and currents from nominal values or states.
Under normal operating conditions, power system equipment or lines carry normal voltages
and currents which results in safer operation of the system. ... Those are symmetrical and
unsymmetrical faults

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If the correct voltage is not present, then the control fuse is open. If the fuse is open, then
there is either a short circuit or ground fault. If the fuse is not open, then there is an open
circuit fault. This is our first indication that the fault is an open circuit fault.
Short-circuited fault is one of the most dangerous and common faults occurring in power
system, which includes three-phase short circuit, two-phase short circuit, two-phase grounding
short circuit and single-phase grounding short circuit
Maintain the first test probe at the hot wire terminal of the circuit. Remove the second probe
from the neutral terminal then place it on the ground terminal for the circuit. Once more the
multi meter will read "OL" or infinity if the circuit is open or zero if the circuit is functioning
Types of Faults
Electrical faults in three-phase power system mainly classified into two types, namely open
and short circuit faults. Further, these faults can be symmetrical or unsymmetrical faults. Let
us discuss these faults in detail.
Open Circuit Faults
These faults occur due to the failure of one or more conductors. The figure below illustrates
the open circuit faults for single, two and three phases (or conductors) open condition.
The most common causes of these faults include joint failures of cables and overhead lines,
and failure of one or more phase of circuit breaker and also due to melting of a fuse or
conductor in one or more phases.
Open circuit faults are also called as series faults. These are unsymmetrical or unbalanced
type of faults except three phase open fault.

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 Fig 1. open circuit fault

Consider that a transmission line is working with a balanced load before the occurrence of
open circuit fault. If one of the phases gets melted, the actual loading of the alternator is
reduced and this cause to raise the acceleration of the alternator, thereby it runs at a speed
slightly greater than synchronous speed. This over speed causes over voltages in other
transmission lines.
Thus, single- and two-phase open conditions can produce the unbalance of the power system
voltages and currents that causes great damage to the equipment.
Causes
Broken conductor and malfunctioning of circuit breaker in one or more phases.
Effects
 Abnormal operation of the system
Danger to the personnel as well as animals
 Exceeding the voltages beyond normal values in certain parts of the network, which
further leads to insulation failures and developing of short circuit faults.
Although open circuit faults can be tolerated for longer periods than short circuit faults, these
must be removed as early as possible to reduce the greater damage.

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Short Circuit Faults
A short circuit can be defined as an abnormal connection of very low impedance between two
points of different potential, whether made intentionally or accidentally.
These are the most common and severe kind of faults, resulting in the flow of abnormal high
currents through the equipment or transmission lines. If these faults are allowed to persist
even for a short period, it leads to the extensive damage to the equipment.
Short circuit faults are also called as shunt faults. These faults are caused due to the insulation
failure between phase conductors or between earth and phase conductors or both.
The various possible short circuit fault conditions include three phases to earth, three phase
clear of earth, phase to phase, single phase to earth, two phase to earth and phase to phase plus
single phase to earth as shown in figure.
The three-phase fault clear of earth and three phase faults to earth are balanced or symmetrical
short circuit faults while other remaining faults are unsymmetrical faults.

Fig2. phase to phase circuit fault

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Fig3. phase to phase plus single-phase circuit fault
Causes
These may be due to internal or external effects
 Internal effects include breakdown of transmission lines or equipment, aging of
insulation, deterioration of insulation in generator, transformer and other electrical
equipment, improper installations and inadequate design.
 External effects include overloading of equipment, insulation failure due to lighting
surges and mechanical damage by public.
Effects
 Arcing faults can lead to fire and explosion in equipment such as transformers and
circuit breakers.
 Abnormal currents cause the equipment to get overheated, which further leads to
reduction of life span of their insulation.
 The operating voltages of the system can go below or above their acceptance values
that creates harmful effect to the service rendered by the power system.

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  The power flow is severely restricted or even completely blocked as long as the short
circuit fault persists.
Symmetrical and Unsymmetrical Faults
As discussed above that faults are mainly classified into open and short circuit faults and
again these can be symmetrical or unsymmetrical faults.
Symmetrical Faults
A symmetrical fault gives rise to symmetrical fault currents that are displaced with 1200 each
other. Symmetrical fault is also called as balanced fault. This fault occurs when all the three
phases are simultaneously short circuited.
These faults rarely occur in practice as compared with unsymmetrical faults. Two kinds of
symmetrical faults include line to line to line (L-L-L) and line to line to line to ground (L-L-L-
G) as shown in figure below.

Fig4. A. three phase to phase earth B. three phase –phase fault

Occurrence of symmetrical faults is in the range of 2 to 5% of the total system faults.
However, if these faults occur, they cause a very severe damage to the equipment even though
the system remains in balanced condition
The analysis of these faults is required for selecting the rupturing capacity of the circuit
breakers, choosing set-phase relays and other protective switchgear

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Unsymmetrical Faults
The most common faults that occur in the power system network are unsymmetrical faults.
This kind of fault gives rise to unsymmetrical fault currents (having different magnitudes with
unequal phase displacement). These faults are also called as unbalanced faults as it causes
unbalanced currents in the system.
Up to the above discussion, unsymmetrical faults include both open circuit faults (single- and
two-phase open condition) and short circuit faults (excluding L-L-L-G and L-L-L).
The figure below shows the three types of symmetrical faults occurred due to the short circuit
conditions, namely phase or line to ground (L-G) fault, phase to phase (L-L) fault and double
line to ground (L-L-G) fault

Fig5.A. single phase-to phase fault B. Phase to phase C. two –phase- earth
A single line-to-ground (LG) fault is one of the most common faults and experiences show
that 70-80 percent of the faults that occur in power system are of this type. This forms a short
circuit path between the line and ground. These are very less severe faults compared to other
faults.
A line-to-line fault occur when a live conductor get in contact with other live conductor.
Heavy winds are the major cause for this fault during which swinging of overhead conductors
may touch together. These are less severe faults and its occurrence range may be between 15-
20%.

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In double line to ground faults, two lines come into the contact with each other as well as with
ground. These are severe faults and the occurrence these faults is about 10% when compared
with total system faults.
Unsymmetrical faults are analyzed using methods of unsymmetrical components in order to
determine the voltage and currents in all parts of the system. The analysis of these faults is
more difficult compared to symmetrical faults.
This analysis is necessary for determining the size of a circuit breaker for largest short circuit
current. The greater current usually occurs for either L-G or L-L fault.
Protection Devices against Faults
When the fault occurs in any part of the system, it must be cleared in a very short period in
order to avoid greater damage to equipment and personnel and also to avoid interruption of
power to the customers.
The fault clearing system uses various protection devices such as relays and circuit breakers to
detect and clear the fault.
Some of these faults clearing or faults limiting devices are given below.
Fuse
It opens the circuit whenever a fault exists in the system. It consists of a thin copper wire
enclosed in a glass or a casing with two metallic contacts. The high fault current rises the
temperature of the wire and hence it melts. A fuse necessitates the manual replacement of wire
each time when it blows.
Circuit Breaker
It is the most common protection device that can make or break the circuit either manually or
through remote control under normal operating conditions.
There are several types of circuit breakers available depending on the operating voltage,
including air brake, oil, vacuum and SF6 circuit breakers. For more information on circuit
breakers, follow the link attached.
Protective Relays
These are the fault detecting devices. These devices detect the fault and initiate the operation
of the circuit breaker so as to isolate the faulty circuit. A relay consists of a magnetic coil and
contacts (NC and NO). The fault current energizes the coil and this causes to produce the
field, thereby the contacts get operated.

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 Fig 6. protective relay
Some of the types of protective relays include
 Magnitude relays  Pilot relays
 Impedance relays  Differential relays
 Directional relays
Lighting Arrestor
Surges in the power system network caused when lightning strikes on transmission lines and
equipment. This causes high voltage and currents in the system. These lighting faults are
reduced by placing lighting arrestors at transmission equipment
In order to control workplace hazards and eliminate or reduce the risk, you should take the
following steps:
 Identify the hazard by carrying out a workplace risk assessment;
 Determine how employees might be at risk;
 Evaluate the risks;
 Record and review hazards at least annually, or earlier if something changes.

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1.6. Faults symptoms and their cause

Visual faults breakdown or inspection refers to a systematic examination of

equipment, machinery, structures, or work areas to identify visual defects, faults, or
deficiencies that may compromise safety or performance. This type of inspection relies
on visual observation and can help detect issues that are visible to the naked eye. Here
is a breakdown of the visual fault‟s breakdown or inspection process:

Preparation: Before starting the inspection, gather relevant information about the
equipment or area to be inspected. This may include equipment manuals, maintenance
records, safety guidelines, and any specific inspection checklists or procedures.

Safety Measures: Ensure proper safety measures are in place. This may involve
wearing appropriate personal protective equipment (PPE), such as safety glasses,
gloves, or hard hats, and following any necessary lockout/tagout procedures.

Visual Observation: Conduct a thorough visual examination of the equipment,

machinery, or work area. Pay attention to details and look for signs of wear, damage,
corrosion, leaks, lose or missing components, or any other visual abnormalities.
Inspect from different angles and distances to ensure comprehensive coverage.

Checklists and Guidelines: Utilize checklists, guidelines, or standard operating

procedures (SOPs) specific to the equipment or area being inspected. These documents
can serve as a reference to ensure all critical components or areas are inspected and
help identify common faults or issues.

Documentation: Document any observed faults or deficiencies. Take notes,

photographs, or videos as necessary to provide clear evidence of the identified faults.
Include details such as the location, description, severity, and potential impact of each
fault.

Actionable Steps: Determine the appropriate course of action for each identified fault.
This may involve immediate corrective measures, scheduling repairs or maintenance,
notifying relevant personnel, or initiating further investigations if necessary.

Priority and Severity: Assess the priority and severity of each identified fault.
Determine which faults pose the highest risk to safety, operations, or compliance and
prioritize their resolution accordingly.

Reporting and Communication: Compile the inspection findings into a

comprehensive report. Clearly communicate the identified faults, their potential
impact, and recommended actions to relevant stakeholders, such as supervisors,
maintenance personnel, or safety committees.

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 Follow-Up and Verification: Ensure that the recommended actions are implemented
within the specified timeframe. Conduct follow-up inspections or verifications to
confirm that the identified faults have been properly addressed and resolved.

Continuous Improvement: Use the inspection findings to identify trends, recurring

faults, or systemic issues. Analyze the data to implement preventive measures, such as
improving maintenance procedures, enhancing training programs, or modifying
equipment design to minimize the occurrence of similar faults in the future.

1.7. Visual fault/breakdown inspection

A visual fault/breakdown inspection is a systematic examination of electrical equipment to

identify any visible signs of damage or defects. This type of inspection can be performed on a
variety of electrical equipment, including:
Electrical panels
 Circuit breakers  Lighting fixtures
 Fuses  Motors
 Switches  Transformers
 Outlets  Generators
 Wiring
To perform a visual fault/breakdown inspection, the following steps should be taken:
Disconnect the power to the equipment being inspected.
 Remove any covers or panels that obstruct the view of the internal components.
 Inspect the equipment for any signs of damage, such as:
 Burned wires
 Loose connections
 Cracked insulation
 Rust or corrosion
 Overheating
 Discoloration
 Swelling
 Leaking fluids
If any signs of damage are found, the equipment should be taken out of service and
repaired or replaced.

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 It is important to note that a visual fault/breakdown inspection is not a substitute for a
comprehensive electrical inspection. A comprehensive electrical inspection should be
performed by a qualified electrician on a regular basis to ensure the safety and
reliability of your electrical system.

Fig 7. visual fault inspection

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Table 1- report format

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 Self-check #1

I. Choose the correct answer from the give alterative

1. Which of the following is NOT a step in troubleshooting electrical faults?
A. Identifying the fault C. Testing the circuit
B. Repairing the fault D. Replacing the circuit
2. Which of the following is NOT a safety precaution to take when troubleshooting
electrical faults?
A. Wearing safety glasses C. Working on live circuits
B. Using insulated tools D. Turning off the power to the circuit
3. Which of the following is a common cause of electrical faults?
A. Loose connections C. Faulty wiring
B. Overloaded circuits D. all
4. Which of the following is NOT a visual symptom of an electrical fault?
A. Scorched wires C. Burning smell
B. Tripped circuit breaker D. Loose connections
II Matching:
. Direction: Match Column A with Column B. Write the letter only.
Colmen A Colmen B
1. No power to the circuit A. Open circuit
2.Circuit breaker trips frequently B. Short circuit
3. Tingling sensation when touching the circuit C. Ground fault
4. Sparks and smoke from the circuit D. Overloaded circuit
5.To protect your eyes from flying debris E. Wear safety glasses
6.To prevent electrical shock F. Use insulated tools
7.To avoid working on live circuits G. Turn off the power to the circuit
III Short answer
1.What is the importance of troubleshooting electrical faults?
2.What are some of the challenges of troubleshooting electrical faults?

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UNIT TWO: TROUBLE-SHOOTING AND REPAIRING FAULTS

This unit is developed to provide you the necessary information regarding the following content
coverage and topics:

 Circuits/Machines/plants

 Equipment and associated

 Circuit Testing procedure of Trouble-shooting

 Methods and technique of trouble-shooting

 Circuit and wiring diagrams

 Critical aspects of trouble-shooting

Visual fault/breakdown inspectionThis unit will also assist you to attain the learning outcomes
stated in the cover page. Specifically, upon completion of this learning guide, you will be able
to:
 Inspect Circuits, Machines and plants
 Repair equipment and associated
 Identify Circuit Testing procedure of Trouble-shooting
 Inspect methods and technique of trouble-shooting
 Understand Circuit and wiring diagrams
 Identify Critical aspects of trouble-shooting

2.1. Circuits, Machines and plants

To troubleshoot and repair faults in electrical circuits, machines, and plants, it is important to
follow safety guidelines.
Identify the problem: What is the specific problem that is occurring? Is there no power? Is
the machine not working properly? Is the plant not producing the desired output?
Gather information: What information is available about the problem? This may include
information about the equipment involved, the environment, and the people who are using it.

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Generate hypotheses: What are the possible causes of the problem? Consider all of the
factors that could be contributing to the problem, such as the equipment, the environment, and
the people who are using it.
Test the hypotheses: Test each hypothesis to determine if it is the cause of the problem. This
may involve inspecting the equipment, running diagnostic tests, or changing the operating
conditions.
Implement a solution. Once the cause of the problem has been identified, implement a
solution to resolve it. This may involve repairing the equipment, changing the operating
conditions, or training the people who are using the equipment.
Verify the solution. Test the solution to ensure that it has resolved the problem.
Here are some additional tips for troubleshooting circuits, machines, and plants:
Be systematic. Don't just start tinkering with things randomly. Follow a logical process to
identify and resolve the problem.
Document your steps. This will help you to keep track of what you have done and to avoid
making the same mistakes again.
Ask for help. If you are stuck, don't be afraid to ask for help from a colleague or supervisor.
It is important to note that some troubleshooting tasks can be dangerous, especially if you are
working with high-voltage electricity or with moving machinery. It is important to follow all
safety precautions and to wear appropriate personal protective equipment (PPE) when
troubleshooting circuits, machines, and plants
 Inspect single phase motor and control for any obvious damage. Look for loose
connections, burnt wires, or damaged components.

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 Fig 8. Check single phase motor

Make sure that all of the components in the control circuit are working properly. You can use
a multimeter to test the components.
Troubleshooting steps
Check the power supply. Make sure that the motor is plugged in and that the power switch is
turned on.
Check the fuse or circuit breaker. If it is blown or tripped, reset it or replace the fuse.
Check the wiring. Make sure that all of the connections are tight and that there are no breaks
in the wires.
Check the contactor. Disconnect the power to the motor and then use a multimeter to check
the continuity of the contactor contacts. If the contacts are not closed, the contactor is faulty
and needs to be replaced.
Check the overload relay. Disconnect the power to the motor and then use a multimeter to
check the continuity of the overload relay contacts. If the contacts are not closed, the overload
relay is faulty and needs to be replaced.
Check the motor windings. If the motor windings are open or shorted, the motor will not
start.

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Troubleshooting and repairing a faulty contactor in a three-phase motor control:
Identify the problem: The first step is to identify the problem with the contactor. This can be
done by checking for the following symptoms:
 The motor is not starting up.
 The motor is running intermittently.
 The motor is running slowly.
 The motor is making unusual noises.
 The contactor is hot or sparking.
Inspect the contactor: Once you have identified the problem, inspect the contactor for any
signs of damage, such as:

 Burned or melted contacts.

 Cracked or broken housing.
 Loose or corroded connections.
Test the contactor: If the contactor is damaged, it will need to be replaced. However, if the
contactor is not damaged, you can test it to see if it is working properly. To do this, you will
need to use a multimeter or voltage tester.
To test the contactor with a multimeter:
 Set the multimeter to DC voltage.
 Connect the positive lead of the multimeter to the coil terminal of the contactor.
 Connect the negative lead of the multimeter to the frame of the contactor.
 Apply power to the contactor.
 The multimeter should read the voltage of the power supply.
To test the contactor with a voltage tester:
 Connect the voltage tester to the coil terminal of the contactor.
 Apply power to the contactor.
 The voltage tester should light up if the contactor is working properly.
Repair or replace the contactor: If the contactor is not working properly, it will need to be
repaired or replaced. If the contactor is damaged, it will need to be replaced. However, if the
contactor is not damaged, you may be able to repair it by cleaning the contacts or tightening
the connections.

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Here are some additional tips for troubleshooting and repairing a faulty contactor in a three-
phase motor control:
 Always disconnect the power supply before troubleshooting or repairing the contactor.
 Be careful when handling the contactor, as it may be hot.
 Use the proper tools and safety gear when working on the contactor.
 If you are not comfortable troubleshooting or repairing the contactor yourself, contact
a qualified electrician.
 faulty contactor in a three-phase motor contr.
Causes of electrical faults in three phase motors
There are a number of causes of electrical faults in three-phase motors, including:
Open and partially open circuit phase winding: This fault occurs when one or more of the
phase windings in the motor is broken or damaged. This can be caused by a variety of factors,
such as overheating, vibration, and moisture.
Short and partially short circuit phase winding: This fault occurs when two or more of the
phase windings in the motor come into contact with each other. This can be caused by a
variety of factors, such as insulation failure, loose connections, and damaged windings.
Open circuit rotor: This fault occurs when one or more of the rotor bars in the motor is
broken or damaged. This can be caused by a variety of factors, such as overheating, vibration,
and mechanical stress.

Burnt out phase winding: This fault occurs when one or more of the phase windings in the
motor overheats and burns out. This can be caused by a variety of factors, such as
overloading, poor ventilation, and insulation failure.

Coil shorted to frame: This fault occurs when one or more of the coils in the motor comes
into contact with the frame of the motor. This can be caused by a variety of factors, such as
insulation failure, loose connections, and damaged windings.

Example

A three-phase motor in a factory is not working properly. The motor is making a loud noise
and is not rotating at its normal speed. The electrician is called to troubleshoot the problem.
The electrician discovers that one of the phase windings in the motor has burned out.

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 Fig 9. Check three-phase motor

Safety considerations

It is important to follow all safety precautions when working with electrical systems. When
working with three-phase motors, it is also important to be aware of the risks of electrocution.
Always disconnect the power supply before working on a three-phase motor.

preventing electrical faults in three-phase motors

Here are some preventing electrical faults in three-phase motors:

 Use motors that are properly sized for the load.

 Avoid overloading motors.
 Make sure that motors are properly ventilated.
 Avoid installing motors in hot or humid environments.
 Use surge protection devices to protect motors from voltage spikes.
 Make sure that all connections are tight and secure.
 Have your three-phase motors inspected and serviced by a qualified electrician on a
regular basis.

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Fault Finding – Three Phase Motors

Problem Possible Cause Tests Solution

Motor will not start. Fault with supply. Check for correct voltage at Fit new fuses, reset circuit
motor terminals. breakers, etc.
Motor or load locked up.
Make sure motor and load are Remove clamps, locks, etc.
Wrong connections in control
free to turn.
circuit. Sort out control circuit.
Check to ensure contactors
operate.

Supply or started Wrong or loose connections. Check all connections are Fix up connections.
trips out at start. properly connected.
Motor overloaded. Change motor for correct
Check load performance data size.
Inertia of load to high.
against motor performance data.
Change cables for correct
Low Voltage due to volt drop in
Measure voltage at motor size.
cables
terminals while motor starting.
Correct setting of overload or
Overload or circuit breaker
Check settings of overload and breaker or change.
incorrectly set or sized.
CB & allow for starting current.

Motor starts but has Incorrect connection. Check connection diagram and Sort out and correct
no torque. Motor nameplate data. connections.
Delta wound motor connects in
does not reach full
star. Check load performance data Check timer and starter
speed or takes a
against motor performance data. control circuit.
long time to Star/Delta starter staying in Star.
accelerate. Measure voltage at motor Change motor for correct
Inertia of load to high.
terminals while motor starting size.

Motor overloaded.
Change cables for correct
Low voltage due to volt drop in size.

cables.

Motor Overheating. Motor overloaded. Check load performance data. Fix problem with load or fit

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 Ineffective cooling. Check fan and air flow. Look for larger motor.
buildup of dirt.
Wrong connection. Clean motor. Sort out cooling
Check connection diagram and of air flow.
Delta wound motor in star.
nameplate data.
Sort out connections.
Supply voltage unbalanced.
Measure phase to phase voltage
Restore supply to all phases.
accurately

Balance supply.

No load amps in Incorrect connection Check connection diagram and Sort out and correct
excess of Full load nameplate data. connections at motor
Star wound motor connection
amps terminals.
Delta. Measure voltage at motor
terminals. Correct supply voltage
Voltage in excess of nameplate.
Compare supply voltage and Change motor for correct
Motor supplied for different
frequency to nameplate. voltage and frequency
voltage or frequency.

Mechanical Noise Thrust from load or Check gap between coupling Re-align couplings
or Vibration. Noisy misalignment. halves and alignment.
Clean bearing housing,
bearings. Bearings
Damaged bearings, too much Turn shaft slowly by hand and change bearings and repack
overheating.
grease, no grease, or foreign feel for roughness or stiffness. with fresh grease.
matter in grease. Check for bent shaft or fan
Fix up out of balance items.
rubbing.
Rotor pulling or foreign matter
Loosen belt tension.
in air gap. Run motor disconnected from
load and then with pulley or Increase strength of
Out of balance load, coupling or
coupling removed. foundations
pulley.
Run motor without belts.
Excessive belt pull.
Check design and construction
Motor foundations not rigid.
foundations

Motor amps in Motor overloaded. Check load and performance Fix problem with load or fit
excess of nameplate data. larger motor.
Low supply voltage.
full load amps on

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load Wrong voltage or frequency. Measure voltage at motor Fix problem, maybe with
terminals larger cables.
Wrong Connections.
Check nameplate. Correct voltage or frequency.
Motor „Single-Phasing‟.
Check nameplate Sort out and correct.
Supply voltage unbalanced.
. Check volts and amps in all Restore balanced supply to
Motor Speed not matched to
three phases. all three phases.
load.
Measure motor speed and check Change motor for correct
load speed requirements. motor speed.

Excessive electric Wrong connections. Check connections Fix up connections

noise
Wrong voltage. Check voltage with nameplate Correct voltage.

Motor „Single-Phasing‟. Check volts with amps in all Restore supply to all three
three phases. phases.

Unbalanced amps Unbalanced supply voltage Measure phase to phase voltage Balance supply or accept
in different phases accurately unbalance
when motor loaded

Motor runs in Wrong connections. Watch shaft rotation Swop and two phases of
wrong direction supply.

Synchronous machines
Synchronous machines are electrical machines that operate at a constant speed, synchronized
with the frequency of the electrical system to which they are connected. They can be used as
either motors or generators.
Synchronous motors are used in a variety of applications, including industrial drives, power
generation, and transportation. They are known for their high efficiency and ability to provide
constant torque over a wide speed range.
Synchronous generators are used to generate electrical power in power plants. They are also
used in wind turbines and other renewable energy systems.

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Fig 10. Synchronous machine
Common problems with synchronous machines include:
Overheating: This can be caused by overloading the machine, poor ventilation, or a failure of
the cooling system.
Vibration: This can be caused by a misalignment of the machine, a loose bearing, or a
damaged rotor.
Noise: This can be caused by a vibration, a rubbing of parts, or a failure of a bearing.
Electrical problems: These can include short circuits, open circuits, or a failure of the
insulation.
Here are some tips for troubleshooting synchronous machines:
 Check the machine for signs of overheating, vibration, noise, and electrical problems.
 Inspect the machine for any obvious damage.
 Check the alignment of the machine.
 Check the bearings for wear and tear.
 Check the insulation for damage.

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Additional of Problem Synchronous machine will not start.
Possible causes:
 Power failure  Faulty exciter
 Blown fuse  Faulty synchronizing system
 Tripped circuit breaker  Faulty rotor windings
 Open circuit in the wiring  Faulty stator windings

Troubleshooting:
Check the power supply: Make sure that the synchronous machine is plugged in and that the
power switch is turned on.
Check the fuse or circuit breaker: If it is blown or tripped, reset it or replace the fuse.
Check the wiring: Make sure that all of the connections are tight and that there are no breaks
in the wires.
Check the exciter: Disconnect the power to the synchronous machine and then use a
multimeter to check the output of the exciter. If the output is not correct, the exciter is faulty
and needs to be repaired or replaced.
Check the synchronizing system: Disconnect the power to the synchronous machine and
then use a multimeter to check the continuity of the synchronizing system wiring. If the
wiring is not continuous, the synchronizing system is faulty and needs to be repaired or
replaced.
Check the rotor windings: Disconnect the power to the synchronous machine and then use a
multimeter to check the continuity of the rotor windings. If the windings are not continuous,
the rotor windings are faulty and need to be repaired or replaced.
Check the stator windings: Disconnect the power to the synchronous machine and then use a
multimeter to check the continuity of the stator windings. If the windings are not continuous,
the stator windings are faulty and need to be repaired or replaced.
Repairing the fault: Once you have identified the cause of the fault, you can proceed to
repair it. If the fault is in the wiring, simply tighten the connections or repair the broken wires.
If the fault is in the exciter, synchronizing system, rotor windings, or stator windings, replace
the faulty component.

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 DC machines
DC machines are electric machines that convert DC electrical energy into mechanical energy
or vice versa. They are used in a wide variety of applications, including electric vehicles,
industrial robots, and machine tools.
Ward-Leonard control: Ward-Leonard control is a classic method of DC machine control
that uses two motor-generator sets to control the speed and torque of a DC motor.
Thyristor control: Thyristor control is a more modern method of DC machine control that
uses thyristors to control the voltage and current applied to the DC motor.
Microprocessor control: Microprocessor control is the most advanced method of DC
machine control and allows for precise control of the speed and torque of the DC motor.
Inspect the machine and control for any obvious damage. Look for loose connections,
burnt wires, or damaged components.

Fig 11. Check DC machine

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If you are unable to identify the problem, you may need to consult a qualified electrician.
 If the machine is not starting, check the starter. Make sure that the starter is turned on
and that the starter contacts are closing.
 If the machine is running but not at full speed, check the machine control circuit. Make
sure that the machine control circuit is providing the correct voltage and current to the
machine.
 If the machine is overheating, check the ventilation around the machine. Make sure
that the machine is not being blocked by any objects.
 If the machine is making strange noises, check the bearings. Make sure that the
bearings are lubricated and that they are not worn out. Inspect the transformer and
auxiliary for any obvious damage.
Transformer and auxiliary component:
A transformer is a static electrical device that transfers energy from one circuit to another
through electromagnetic induction. A varying current in the first circuit (the primary) creates a
varying magnetic field in the transformer, which in turn induces a varying current in the
second circuit (the secondary). Transformers can be used to increase or decrease voltage, and
they are also used to isolate circuits from each other.

Fig 12. Test secondar voltage transformer

Auxiliary transformer
An auxiliary transformer is a type of transformer that is used to provide a secondary voltage
source for auxiliary equipment. Auxiliary equipment includes things like cooling fans, pumps,

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and control systems. Auxiliary transformers are typically smaller than power transformers,
and they are often located inside the same enclosure as the equipment they are powering.
Examples of transformers and auxiliary components
Transformers:
Power transformers: These are used to transmit and distribute electricity over long distances.
Distribution transformers: These are used to step down the voltage from power transformers
to a level that is safe for use in homes and businesses.
Electronic transformers: These are used in a variety of electronic devices, such as computers
and televisions.
Auxiliary components:
Auxiliary transformers: These are used to provide a secondary voltage source for auxiliary
equipment.
Cooling fans: These are used to keep electronic equipment from overheating.
Pumps: These are used to circulate fluids in a variety of applications, such as heating and
cooling systems.
Control systems: These are used to monitor and control electrical systems.
Troubleshooting transformers and auxiliary components
There are a number of things that can go wrong with transformers and auxiliary components.
Some common problems include:
 Overheating  Ground faults
 Overloading  Insulation failure
 Short circuits
Here are some tips for troubleshooting transformers and auxiliary components:
Check the temperature of the transformer. If it is overheating, it may be overloaded or
have a ventilation problem.
Check the load on the transformer. If it is overloaded, it may need to be replaced with a
larger transformer.
Check for short circuits and ground faults. These can be detected using a variety of test
instruments.
Inspect the insulation for signs of damage. If the insulation is damaged, it may need to be
replaced.

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Repairing the fault:
Once you have identified the cause of the fault, you can proceed to repair it. If the fault is in
the wiring, simply tighten the connections or repair the broken wires. If the fault is in the
transformer bushing, conservator, breather, tap changer, or windings, replace the faulty
component.
Causes of faults in ELV lighting devices,
There are a number of causes of faults in ELV lighting devices, including:
Transformer (iron core or electronic): Transformers can fail due to a number of reasons,
such as overloading, overheating, or voltage spikes.
Voltage drops: If the voltage at the ELV device is too low, the device may not work properly
or may fail altogether.
Heat: ELV devices can be sensitive to heat, and overheating can cause them to fail.
Over-voltage: If the voltage at the ELV device is too high, the device may be damaged or
destroyed.
Poor connections: Loose or corroded connections can cause a variety of problems with ELV
devices, including flickering, dimming, and complete failure.
Incompatible dimmers: Using an incompatible dimmer with an ELV device can damage or
destroy the device.
Example
An ELV lighting system in a house is not working properly. The homeowner has tried
replacing the bulbs, but the problem persists. The homeowner then calls an electrician to
troubleshoot the problem. The electrician discovers that the transformer for the ELV system
has failed. The electrician replaces the transformer and the ELV system starts working
properly again.
preventing faults in ELV lighting devices
Here are some tips for preventing faults in ELV lighting devices
Use a transformer that is properly sized for the load.
 Avoid overloading the transformer.
 Make sure that the ELV devices are properly ventilated.
 Avoid installing ELV devices in hot or humid environments.
 Use surge protection devices to protect the ELV devices from voltage spikes.

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  Make sure that all connections are tight and secure.
 Use compatible dimmers with ELV devices.
 Have your ELV lighting system inspected and serviced by a qualified electrician on a
regular basis.
2.2. Equipment and associated

The correct operation of a circuit or equipment is essential to ensure safety and reliability.
Switching and control circuit arrangements are used to control the flow of electricity in a
circuit. They can be used to turn equipment on and off, to select different operating modes, or
to protect equipment from damage.
Here is an example of a switching and control circuit arrangement for a simple lighting
circuit:

fig. 13. simple lighting circuit

The switching and control circuit arrangement in this example consists of a single-pole,
single-throw (SPST) switch. The switch is connected in series with the light bulb and the
power supply. When the switch is turned on, current flows through the circuit and the light
bulb turns on. When the switch is turned off, the circuit is interrupted and the light bulb turns
off.

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Troubleshooting. simple lighting circuit
Here are some common problems that can occur with a simple lighting circuit and how to
troubleshoot them:
Light bulb does not turn on:
 Check the light bulb to make sure it is not burned out.
 Check the switch to make sure it is turned on.
 Check the wiring connections to make sure they are tight and secure.
If the problem persists, use a voltage tester to check the voltage at the light bulb socket. If
there is no voltage, the problem may be with the power source or the wiring.
Light bulb flickers:
 Check the wiring connections to make sure they are tight and secure.
 Check the switch to make sure it is making good contact.
 If the problem persists, the problem may be with the light bulb itself.
Light bulb burns out prematurely:
 Check the voltage at the light bulb socket. If the voltage is higher than the voltage
rating of the light bulb, it will cause the light bulb to burn out prematurely.
 Check the ventilation around the light bulb. If the light bulb is not properly ventilated,
it will overheat and burn out prematurely.
motor control circuit
motor control circuit arrangements can be much more complex than the simple example
above. For example, a motor control circuit arrangement for a motor control circuit might
include a contactor, a starter, and a variety of other components.:

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Fig 14. Check motor control circuit
Troubleshooting motor control circuit
Here are some common problems that can occur with a motor control circuit and how to
troubleshoot them:
Motor does not turn on:
 Check the switch to make sure it is turned on.
 Check the wiring connections to make sure they are tight and secure.
 Use a voltage tester to check the voltage at the motor contactor terminals. If there is no
voltage, the problem may be with the power source or the wiring.
 If there is voltage at the motor contactor terminals, check the motor contactor to make
sure it is operating properly.
Motor runs but is noisy:
 Check the motor bearings to make sure they are lubricated properly.
 Check the motor shaft to make sure it is not bent or damaged.
 Check the motor belts or chains to make sure they are properly tensioned.

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Motor overheats:
 Check the motor ventilation to make sure it is not blocked.
 Check the motor load to make sure it is not overloaded.
 Check the motor bearings to make sure they are lubricated properly.
Operator faults:
 Accidentally turning off a switch or  Loose or corroded connections
breaker  Incorrectly sized wires
 Using incorrect wiring procedures  Incorrectly wired outlets or
 Overloading a circuit switches
 Incorrect connections:
Open-circuits:
 Broken wires
 Blown fuses or tripped breakers
 Faulty devices
Short-circuits:
 Exposed wires touching each other
 Damaged insulation
 Faulty devices
Device faults (mechanical):
 Worn or broken parts
 Malfunctioning switches
 Overheated components
Supply faults:
 Low or high voltage
 Power outages
 Faulty wiring at the service panel
Here are some images of common faults with circuits and equipment:

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 fig 15. faults with circuits
If you experience any of the following symptoms, it is important to have the circuit or
equipment inspected by a qualified electrician:
 Tripping breakers or blown fuses  Overheated devices
 Dimming lights  Equipment that does not work
 Sparks or arcing properly
 Burning smell
Circuit protective device
 Symptom: Circuit breaker trips or fuse blows.
 Causes: Overcurrent, short circuit, ground fault, faulty device.
Appliance does not operate:
 Symptom: Appliance does not turn on or does not work properly.
 Causes: Open circuit, faulty device, power supply problem.
Single phase motor does not develop enough torque to drive the load:
 Symptom: Motor runs but does not have enough power to turn the load.
 Causes: Low voltage, overloaded motor, faulty motor.

Three phase motor does not develop enough torque to drive the load:
 Symptom: Motor runs but does not have enough power to turn the load.
 Causes: Unbalanced voltage, overloaded motor, faulty motor.
Motor overload
 Symptom: Motor overload protection device.
 Causes: Overloaded motor, faulty motor, ventilation problem.

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troubleshooting electrical faults
Here are some tips for troubleshooting electrical faults:
 Identify the symptoms. What is the problem that you are experiencing? Is it a tripped
circuit breaker, a non-working appliance, or a motor that is not developing enough
torque?
 Check the circuit protective devices. Are any circuit breakers tripped or fuses blown?
If so, reset the circuit breaker or replace the fuse.
 Check the power supply. Is there power at the outlet or switch? If not, check the
service panel to make sure that the main breaker is not tripped.
 Check the connections. Are all of the connections tight and secure? Loose connections
can cause a variety of problems, including overheating, sparking, and equipment
failure.
2.3. Circuit Testing procedure of Trouble-shooting

Check the devices themselves. If you have checked all of the above and the problem persists,
it is likely that one of the devices on the circuit is faulty. Try disconnecting the devices one by
one until you find the faulty device Identify the symptoms. What is the problem that you are
experiencing? Is it a tripped circuit breaker, a non-working appliance, or a motor that is not
developing enough torque?
Visually inspect the circuit. Look for any obvious signs of damage, such as loose
connections, burned wires, or scorched components.
Test the circuit for voltage. Use a voltmeter to measure the voltage at different points in the
circuit. If the voltage is below or above normal, this could be a sign of a problem.
Test the circuit for continuity. Use a continuity tester to check for continuity of the circuit.
If there is no continuity, this means that there is a break in the circuit.
Test the circuit for ground faults. Use a ground fault tester to check for ground faults in the
circuit. If there is a ground fault, this means that there is a current leakage from the circuit to
ground.

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2.4. Methods and technique of trouble-shooting

There are a number of different methods and techniques that can be used for troubleshooting
electrical systems. Some of the most common methods include:
Visual inspection: This involves inspecting the electrical system for any obvious signs of
damage, such as loose connections, burned wires, or scorched components.
Voltage testing: This involves using a voltmeter to measure the voltage at different points in
the electrical system. This can help to identify problems with the power supply or with
individual components.
Continuity testing: This involves using a continuity tester to check for continuity in the
electrical system. This can help to identify breaks in the wiring or in individual components.
Ground fault testing: This involves using a ground fault tester to check for ground faults in
the electrical system. This can help to identify problems with the wiring or with individual
components.
Signal tracing: This involves using a signal tracer to track the signal through an electrical
system. This can help to identify problems with the wiring or with individual components.
In addition to these general methods, there are also a number of specific troubleshooting
techniques that can be used for different types of electrical systems. For example, there are
specific troubleshooting techniques for AC circuits, DC circuits, electronic circuits, and power
systems.
Example:
A homeowner is having problems with their kitchen lights. The lights are flickering and
sometimes they don't turn on at all. The homeowner decides to troubleshoot the problem
themself.
The homeowner then uses a ground fault tester to check for ground faults in the
electrical system. There are no ground faults.
The homeowner is now stumped. They have checked all of the obvious things and they still
can't figure out why the lights are flickering and sometimes not working in the wiring box
behind the light switch. The electrician tightens the connection and the lights start.
The homeowner decides to call a qualified electrician. The electrician comes to the house and
inspects the electrical system.

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Fig 16. Testing circuit breaker
troubleshooting electrical systems:
Start by identifying the symptoms of the problem: What is not working? What are the
symptoms of the problem? Once you have identified the symptoms, you can begin to narrow
down the possible causes.
Gather information: This includes gathering information about the electrical system, the
components involved, and the environment. You should also gather information about the
symptoms of the problem, when it started, and any changes that have been made to the system
recently.
Form a hypothesis: Based on the information you have gathered you can begin to form a
hypothesis about the cause of the problem. This is your best guess about what is wrong with
the system.
Test the hypothesis: Once you have a hypothesis, you need to test it to see if it is correct.
This may involve performing experiments, making measurements, or inspecting the system.
Analyze the results: Once you have tested your hypothesis, you need to analyze the results to
see if they support your hypothesis. If the results do not support your hypothesis, you need to
go back and form a new hypothesis.
Fix the problem: Once you have identified the cause of the problem, you can fix it. This may
involve repairing a component, replacing a component, or making changes to the system.

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2.5. Circuit and wiring diagrams

Circuit diagrams and wiring diagrams are important tools for troubleshooting electrical
installations in buildings. Circuit diagrams show how the electrical components in a circuit are
connected, while wiring diagrams show the physical layout of the electrical wires and devices.
To troubleshoot an electrical problem in a building, it is helpful to have a circuit diagram and
wiring diagram for the circuit in question. This will help you to identify the components that
are involved in the circuit and to trace the path of the electrical current.
Here are some troubleshooting electrical installations in buildings using circuit diagrams and
wiring diagrams:
Identify the circuit that is affected by the problem. To do this, you can use the circuit
diagram to trace the path of the electrical current from the power source to the load (e.g., light
bulb, outlet, etc.).
Once you have identified the circuit, use the wiring diagram to locate the electrical
components in the circuit. This will help you to identify the component that is causing the
problem.
Once you have identified the component that is causing the problem, you can troubleshoot
the component to determine the specific cause of the problem. This may involve using a
variety of test instruments, such as a multimeter or a voltage tester.
Once you have determined the specific cause of the problem, you can repair the problem
or replace the component if necessary.
Here are some examples of how to use circuit diagrams and wiring diagrams to troubleshoot
common electrical problems in buildings:
Problem: A light bulb is not working.
Troubleshooting:

 Use the circuit diagram to identify the circuit that the light bulb is on.
 Use the wiring diagram to locate the light bulb socket and the switch that controls the
light bulb.
 Check to make sure that the switch is turned on.
 Check the light bulb to make sure that it is not burned out.

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  If the light bulb is not burned out, use a voltage tester to check the voltage at the light
bulb socket. If there is no voltage, the problem may be with the switch, the wiring, or
the power source.
 If there is voltage at the light bulb socket, the problem may be with the light bulb
itself.
Problem: A circuit breaker is tripping frequently.
Troubleshooting:
 Use the circuit diagram to identify the circuit that the circuit breaker is protecting.
 Use the wiring diagram to locate all of the electrical components on the circuit.
 Check all of the electrical components on the circuit for signs of damage or
overheating.
 If you cannot find any signs of damage or overheating, you may need to reduce the
load on the circuit by unplugging some of the electrical devices that are connected to
it.
 If the circuit breaker continues to trip after you have reduced the load, you may need
to replace the circuit breaker.
basic fluorescent light circuit
Fluorescent lamp: The fluorescent lamp is a glass tube that is filled with a low-pressure
mercury vapor. When an electric current is applied to the lamp, the mercury vapor emits
ultraviolet light. This ultraviolet light causes the phosphor coating on the inside of the lamp to
glow, which produces visible light.
Ballast: The ballast is a transformer that provides the high voltage and current needed to start
and operate the fluorescent lamp. The ballast also regulates the current flowing through the
lamp to prevent it from overheating.
Starter: The starter is a switch that is used to start the fluorescent lamp. When the power is
turned on, the starter closes and allows current to flow through the lamp. Once the lamp is
started, the starter opens and disconnects itself from the circuit.

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Fig 17. Fluorescent lamp.
Problem: Fluorescent lamp does not turn on.
Troubleshooting
 Check the light bulb to make sure it is not burned out.
 Check the switch to make sure it is turned on.
 Check the wiring connections to make sure they are tight and secure.
 Use a voltage tester to check the voltage at the light bulb socket. If there is no voltage,
the problem may be with the power source or the wiring.
 If there is voltage at the light bulb socket, check the ballast to make sure it is operating
properly.
Problem: Fluorescent lamp flickers or buzzes.
Troubleshooting
 Check the wiring connections to make sure they are tight and secure.
 Check the ballast to make sure it is operating properly.
 Check the starter to make sure it is operating properly.
 Check the light bulb to make sure it is not burned out.
Problem: Fluorescent lamp burns out prematurely.
Troubleshooting
 Check the voltage at the light bulb socket. If the voltage is higher than the
voltage rating of the light bulb, it will cause the light bulb to burn out
prematurely.

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  Check the ventilation around the light bulb. If the light bulb is not properly
ventilated, it will overheat and burn out prematurely.
 Check the ballast to make sure it is operating properly.
Some common faults & rectification of fluorescent lamp

No Faults Rectification

Lamp doesn't glow but flicks

Cause: - lamp is defective Replace after testing
1 - Low voltage Check up the voltage
- Defective starter Test the starter.

Lamp doesn't start a) Test the filament.

Cause: - Open circuit in the filament
2 Loose or broken connections b) Test the wire & tighten
the loose connections.
3 Lamp burns out often
Cause: - High voltage Check the voltage
4 Lamp filament glow but not light up.
Cause: - short circuit of the starter contacts test the starter
Capacitor short circuited test and replace condenser

5 Lamp burns out often

Cause: - low voltage check the voltage
Spoiled chock check the chock
Loose connection in the holder and starter Check the lamp holder,
connections, & the starter
contact.
6 Blackening of the lamp at the ends after short use,
Cause: - High voltages checks and reduce the
Choke coil is shorted voltage
test and replace the choke

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2.6. Critical aspects of trouble-shooting

 Identifying the problem: What is happening? What are the symptoms?

 Gathering information: What are the possible causes of the problem? What have you
tried so far?
 Developing a hypothesis: What is the most likely cause of the problem?
 Testing the hypothesis: Try to fix the problem based on your hypothesis.
 Evaluating the results: Did your solution fix the problem? If not, go back to step 3.
Here is an example of troubleshooting a broken toaster:
 Identify the problem: The toaster is not turning on.
 Gather information: The toaster is plugged in and the outlet is working. I have tried
turning the toaster on and off multiple times.
 Develop a hypothesis: The toaster may be broken because of a power cord issue or an
internal problem.
 Test the hypothesis: First, I will try plugging the toaster into a different outlet. If that
does not work, I will try replacing the power cord. If that still does not work, I will
need to open up the toaster and inspect the internal components.
 Evaluate the results: If plugging the toaster into a different outlet fixes the problem,
then the issue was with the original outlet. If replacing the power cord fixes the
problem, then the issue was with the power cord. If neither of those solutions work,
then the issue is likely with an internal component of the toaster and I will need to take
it to a repair shop.

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 I Self-check-2
I. Choose the best answer from the give alterative

1.Which of the following is NOT a type of circuit?

A. AC circuit C. Series circuit

B. DC circuit D. Parallel circuit

2.Which of the following is NOT a type of electrical machine?

A. Motor C. Transformer

B. Generator D. Battery

3.Which of the following is NOT a type of electrical plant?

A. Power plant C. Transmission line

B. Substation D. Distribution line

4.Which of the following is NOT a piece of electrical equipment?

A. Circuit breaker C. Switch

B. Fuse D. Battery

5.Which of the following is NOT a critical aspect of troubleshooting?

A. Identifying the fault C. Testing the circuit

B. Repairing the fault D. Understanding the circuit

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II Matching:
Direction: Match Column A with Column B. Write the letter only.
Column A Column B.
1. measure the voltage across a component A. Voltage test
2.measure the current flowing through a component B. Current test
3. check if a circuit is complete C. Continuity test
4. divide the circuit into smaller sections and test D. Process of elimination
each section individually
5. replace suspected faulty components with known E. Division of the circuit
good components
6. measure the voltage, drop across components F. Substitution method
to identify the faulty component
7.systematically eliminate possible causes of the G. Voltage drop method
fault until the fault is found
III Short answer:
1.What is the purpose of circuit and wiring diagrams?
2.What are some of the challenges of troubleshooting complex electrical systems?

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Operation sheet 1. Steps how to Troubleshooting Electrical apparatus

Steps how to Troubleshooting Electrical apparatus

The following steps will guide you through the preparation and termination process for UTP
cable. Following these guidelines will help give you the optimum performance from the
twisted pair cabling.
Step 1: Gather the information
step 2. Understand the malfunction
step 3. Identify which parameters need to be evaluated
step 4. Identify the source of the problem
step 5. Correct/repair the component
step 6. Verify the repair
step 7. Perform root cause analysis

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Operation sheet 2 Steps how to find Electrical apparatus fault

Steps how to find Electrical apparatus fault

Step 1: Notify what exactly is the problem.
Step 2: Gather more details, eliminate variables.
Step 3: Reproduce the problem.
Steps4: Develop hypothesis of root cause.
Step 5: Attempt a fix based on findings.
Step 6: maintain the fault

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 Lap test

Name………………………………. ID…………………………….
Date…………………………………….
Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 1 hour. The project is expected from each student to do it.

Task: 1. Troubleshooting Electrical apparatus?

Task: 2. Find the faults of Electrical apparatus?
Task: 3. Fix and troubleshoot circuit breaker (CB)?

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UNIT THREE: COMPLETION AND REPORT TROUBLE-SHOOT AND REPAIR
ACTIVITIES
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 justification for repairs to apparatus.
 Documentation and reporting
 Clean and a safe work area
Visual fault/breakdown inspectionThis unit will also assist you to attain the learning outcomes
stated in the cover page. Specifically, upon completion of this learning guide, you will be able
to:
 Protect justification for repairs to apparatus.
 Write documentation and reporting
 Clean and a safe work area safe

3.1. justification for repairs to apparatus

Troubleshooting is a form of problem solving, often applied to repair failed products or

processes on a machine or a system. In general, troubleshooting is the identification or
diagnosis of "trouble" in the management flow of a system caused by a failure of some kind.
There are several justifications for repairs to apparatus in an electrical installation. Here are
some common reasons why repairs may be necessary:
Safety: The primary concern when it comes to electrical installations is safety. If any
apparatus within the installation is damaged or malfunctioning, it can pose a significant risk of
electrical shocks, fires, or other accidents. Repairing the faulty apparatus ensures that the
electrical system operates safely and minimizes the risk of harm to people and property.
Compliance with regulations: Electrical installations are subject to various regulations and
codes to ensure they meet specific safety standards. If any apparatus within the installation is
not functioning correctly or is outdated, it may not comply with the applicable regulations.

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Repairing or replacing the faulty apparatus ensures that the installation remains compliant
with the relevant codes and standards.
Performance and efficiency: Faulty apparatus can lead to a decrease in the performance and
efficiency of the electrical system. For example, damaged wiring or connectors may lead to
voltage drops, power losses, or poor electrical connections. By repairing or replacing the
faulty components, the electrical system can operate at its optimum level, ensuring reliable
performance and efficient energy usage.
Preventive maintenance: Regular maintenance and repairs are essential to prevent more
significant issues from arising in the future. By addressing minor problems promptly, you can
avoid costly breakdowns, extensive repairs, or complete system failures. Repairing the
apparatus in a timely manner helps maintain the integrity and reliability of the electrical
installation.
Equipment lifespan: Apparatus within an electrical installation has a specific lifespan, and
their performance may deteriorate over time. Repairs may be necessary to extend the life of
the apparatus, especially if replacement is not immediately feasible or cost-effective.
Repairing or refurbishing the existing apparatus can help ensure its continued functionality
until a more comprehensive upgrade can be implemented.
Cost savings: Repairing faulty apparatus is often more cost-effective than replacing the entire
system. By identifying and fixing the specific issues, you can minimize expenses while still
maintaining the functionality and safety of the electrical installation. This is particularly
relevant in situations where the faulty apparatus is a component of a larger system that does
not require replacement.
In summary, the justification for repairs to apparatus in an electrical installation revolves
around safety, compliance, performance, preventive maintenance, equipment lifespan, and
cost savings. By addressing and resolving issues promptly, you can ensure the optimal
functioning and longevity of the electrical system while maintaining a safe environment.

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3.2 Documentation and reporting

It is important to document and report all troubleshooting and repair activities. This
documentation should include the following information:
 The date and time of the troubleshooting and repair activities
 The name of the person who performed the troubleshooting and repair activities
 A description of the problem
 A description of the troubleshooting and repair steps that were taken
 The results of the troubleshooting and repair activities
This documentation can be used to track the history of the apparatus and to identify any
recurring problems. It can also be used to train other personnel on how to troubleshoot and
repair the apparatus.
Example:
A technician troubleshoots and repairs a broken toaster. The technician documents the
following information:
 Date and time: -----------------
 Technician name: ------ ----------------
 Description of the problem: The toaster oven is not turning on.
 Description of the troubleshooting and repair steps: The technician checked the power
cord and found that it was damaged. The technician replaced the power cord and the
toaster turned on.
 Results: The toaster oven is now working properly.
The technician also takes a photo of the damaged power cord and attaches it to the
documentation.

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 .

Fig 18. Toaster oven

3.3. Clean and a safe work area

A clean workplace means more than just having a sparkling, fresh building. A clean
workplace also ensures the safety and health of employees and visitors.
Workplace injuries can be prevented by taking action to ensure a clean, safe work
environment
Here are some tips to help make your workplace safe.
 Understand the risks. ...
 Reduce workplace stress. ...
 Take regular breaks. ...
 Avoid stooping or twisting. ...
 Use mechanical aids whenever possible. ...
 Protect your back. ...
 Wear protective equipment to suit the task. ...
 Stay sober.

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10 Easy Workplace Safety
1. Train employees well.
Comprehensive training is a must for preventing workplace injury. Make sure that all of your
employees have access to – and complete – all safety training for their positions.
2. Reward employees for safe behavior.
Rewards are an easy way to encourage workplace safety. Giving out small rewards to
employees who follow safety policies keeps them engaged, which can make a big difference
in reducing workplace injuries.
3. Partner with occupational clinicians.
As mentioned above, occupational medicine clinicians can provide valuable insight into
workplace injury and prevention. These clinicians can help you prevent work injuries by
visiting your worksite and identifying areas where there‟s a high risk for employee injury.
Physical and occupational therapists can also improve workplace ergonomics and develop
human performance evaluations to help you screen candidates for physically demanding roles
and aid in the return-to-work process.
4. Use labels and signs.
Labels and signs are a cheap and effective way to quickly communicate important
information. They‟re usually simple and rely on pictures to detail hazards and proper
procedures. These tools are good reminders and warnings for even the most experienced
worker.
5. Keep things clean.
A messy workplace can lead to unnecessary accidents. Make sure boxes are stacked safely
and spills are cleaned up quickly. Conduct regular inspections to check for potential dangers
such as tangled cords, messy floors, and disorganized tools. Programs like 5S often provide
beneficial improvements in organization that can lead to reduced clutter.
6. Make sure employees have the right tools and have regular equipment inspections.
The right tools and equipment create a better product and a safer work environment. It‟s also
important that all equipment is cleaned, serviced, and inspected regularly. Machine
malfunctions are one of the most dangerous workplace hazards.

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7. Encourage stretch breaks.
Stretch breaks are an easy way to improve workplace ergonomics and employee health.
Taking even five minutes to stretch can ease muscle tension and loosen joints, reducing the
potential for repetitive motion injuries. Active movements have been shown to be more
effective than passive stretching alone.
8. Implement safety protocols from the start.
Workplace safety starts from day one, which means hiring qualified people who pay attention
to detail. A safe workplace starts with employees who follow safety requirements and perform
their jobs per the established procedures. Some employers work with physical therapists to
analyze the physical demands of each job role. The findings are used to create functional job
analyses and post-offer pre-placement functional testing.
9. Keep an open dialogue.
Make it easy for your employees to come to you with health and safety concerns. They can
report hazards right away and identify potential areas of concern you may not have noticed.
Appoint or nominate a safety captain who is empowered to communicate concerns identified
by employees to leadership on a consistent basis.
10. Have regular meetings on workplace safety.
It never hurts to be over-prepared. Regular meetings to review safety rules and discuss
prevention keep workplace safety top of mind so that when something does happen, everyone
knows what to do right away.
As an employer, it‟s your responsibility to protect your employees and provide a safe
workplace. Use these ten tips to get started, and partner with Concentra® to help make your
workplace safe, healthy, and productive.

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Self-check 3

I. Choose the best answer from the give alterative:

1. Which of the following is NOT a valid reason for repairing apparatus?
A. restore the apparatus to its original condition
B. ensure the safe and reliable operation of the apparatus
C. To comply with safety regulations
D. To save money
2.Which of the following documentation should be included in a justification for repairs to
apparatus?
A. description of the apparatus C. Recommendation for the repair
B. description of the fault D. All of the above
II. Matching:
Direction: Match Column A with Column B. Write the letter only.
Column A Column B.
1. justify the cost of the repair A. Apparatus name
2 identify the apparatus that needs to be repaired B. Repair cost
3. describe the work that needs to be done C. Repair description
4.explain why the apparatus needs to be repaired D. Reason for repair
III Short answer:
Why is it important to document and report on repairs to apparatus?
What are some of the challenges of documenting and reporting on repairs to apparatus?

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Reference Materials

1. Electrical Motor Controls for Integrated Systems" by Gary Rockies and Glen Mazur
(Latest edition: 2021)
2. Industrial Electricity and Motor Controls" by Rex Miller and Mark Miller (Latest
edition: 2020)
3. Electrical Wiring Commercial" by Ray C. Mullin and Phil Simmons (Latest edition:
2018)
4. Practical Troubleshooting of Electrical Equipment and Control Circuits" by Mark
Brown (Latest edition: 2016)
5. Electricity and Controls for HVAC-R" by Stephen L. Herman (Latest edition: 2014)

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 Developer’s Profile
Qualificat Organizatio
N Mobile
Name ion Field of Study n/ E-mail
o number
(Level) Institution
Industrial
Lideta
Mengistu Automation & menabiy@gmail.
1 MSc Manufacturi 0913948480
Abiyu Control com
ng College
Management
Industrial
Samuel Automation & Haramaya samuelbekele460
2 MSc 910082977
Bekele Control PTC @gmail.com
Management
Electrical
Yidnekach Automation & www.yidne23@
3 BSc Akaki PTC 920137899
ew Seboka Control gmail.com
Technology
Electrical
Addis
Zegeye Automation & zegeyegirma2@g
4 BSc Ketema 926805563
Girma Control mail.com
In.College
Technology
Industrial
Hawassa
Bacha Automation & bachawake@gm
5 MSc Tegibarid 987065251
Wake Control ail.com
PTC
Management

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