How to Troubleshoot Obscure Electrical Problems in Industrial Settings

As an industrial electrician, I often encounter obscure electrical problems that can be challenging to diagnose and repair. However, with the right troubleshooting approach and tools, even the most obscure issues can be resolved. Here is my step-by-step guide to troubleshooting obscure electrical problems in industrial settings:

Gather Information from Operators and Conduct Visual Inspections

The first step is to gather as much information as possible from the equipment operators about what issues they are noticing with the equipment. I ask questions like:

• When did the problem start occurring? Was there any event that preceded it?
• Is the problem intermittent or consistent?
• What are the exact symptoms you are noticing?
• Has any maintenance or repair work been done recently?

I also conduct thorough visual inspections of all electrical components involved, looking for any signs of damage, wear or abnormalities. I check connections, wire runs, motors, relays, sensors, and control panels. Any issues identified during the inspection provide clues about where potential problems may exist.

Check Power Supply and Electrical Connections

Many obscure electrical issues can be caused by problems with the power supply or loose electrical connections. I methodically check:

• Voltage levels at various points in the circuit to ensure the proper voltage is reaching the equipment. I use a multimeter to compare voltage readings to equipment specifications.
• Electrical connections to make sure lugs are tight and wires are secure. Loose connections can cause intermittent power issues.
• The condition of fuses, breakers, transformers and other power distribution components. Faulty components can impede power delivery.

Tightening loose connections and replacing damaged power distribution parts like breakers often fixes elusive electrical gremlins.

Inspect and Test Individual Components

The next stage is to methodically inspect and test the individual electrical components like motors, relays, sensors, lights, valves and controllers. I:

• Check motor windings for damage.
• Use relay testers to test operation of relays and contactors.
• Confirm sensors are providing accurate readings.
• Perform continuity or resistance tests on wires and coils.
• Wiggle test connections to identify loose wires.

Meticulously testing each component helps pinpoint faults within complex electrical systems.

Analyze Circuits and Logic

Obscure electrical issues can also arise from problems with the control circuit logic or sequencing. I take time to thoroughly analyze the electrical prints to understand how the different components interact within the overall circuit.

Some techniques I use include:

• Confirming the electrical sequence meets the timing requirements of the equipment.
• Drawing out a ladder logic diagram if the system uses relays.
• Using test lights to verify power is reaching the correct points in the circuit as expected.
• Identifying any components activated out of sequence.

Understanding the intended circuit logic and timing helps uncover timing faults or issues with the control logic.

Check for External Factors

Finally, I assess external factors outside the electrical system that could be contributing to the problem:

• Vibration can cause connections to fatigue and fail over time.
• Fluctuations in temperature, humidity or dirt can cause unusual issues.
• Interference from EMI/RFI signals can impact sensitive components.

Ruling out external factors helps isolate the issue within the electrical system itself.

By following these troubleshooting steps, I can systematically track down even the most evasive electrical issues plaguing industrial equipment. While occasional problems may defy quick diagnosis, methodical troubleshooting and an understanding of the equipment will ultimately uncover the root cause.