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How to troubleshoot loose wire, ground fault, or short
How to wire devices, and how electric devices work/pdf
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Troubleshoot
household electricity: general reference for homeowner &
electrician How to troubleshoot loose wire, ground fault, or short How to wire devices, and how electric devices work/pdf |
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imageResidential Main panel Single-phase electric service has 120 and 240 volt circuits. T wires are required to complete each circuit 240 volt circuits consists of 2 Hot wires and a ground wire that supply power to one device, such as pump, clothes dryer, air conditioner. The electric dryer is connected to one 240 volt breaker. The AC is connected to another 240 volt circuit breaker, etc. 120 volt circuits have 1 Hot, 1 Neutral and a ground wire that supply power to lights, fan, outlets etc. with maximum 12 boxes per circuit. Some 120 volt circuits are dedicated, and supply power to one device such as microwave because the appliance consumes the full amp load the breaker can supply. Some power vent water heaters and other electronic devices are on a dedicated breaker to reduce electrical interference. - Generally a 120 volt circuit supplies power to one area of home. The wire leaves breaker box and go to first junction box, which is typically a ceiling box. From the junction box, the wire splits off and goes to each individual box, traveling from box to box to a maximum number of 12 boxes until the final box is reached. Each box will have 1 black hot wire, 1 white neutral wire, and 1 ground wire that connect back to main breaker box. Resources: See inside main breaker box How to replace circuit breaker How to install subpanel Figure volts amps watts for electric water heater Basic house wiring |
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Match
wire size and breaker amp rating
If
you suspect wiring is not correct, call
electrician. If your
home was wired by
professional electrician who pulled permits,
then circuit breaker and wire size will match. If manufactured
home or travel trailer has not been altered by homeowner then breaker
and wire size will match.  Circuit
breaker and wire sizeExample: Use 10 gauge wire with 30 amp breaker. This applies to either 120 or 240 volt: Each appliance and device has a rating plate that identifies volts and watts, or volts and horsepower. Any 120 volt electrical device rated 20 amps requires 20 amp breaker and 12 gauge wire. Any 240 volt electrical device rated 20 amps also requires 20 amp breaker and 12 gauge wire. If wire is too small or breaker is rated too many amps for the wire, then breaker can let too much electricity travel through the wire. Wire can overheat and cause fire. Always match wire and breaker size. Household NM-B Wires are color-coded so inspectors/ electricians can easily identify which wire is used during construction. Resource: Match breaker and wire size |
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| Copper wire vs aluminum Do not use aluminum wire. Copper wire is safe. Aluminum wire expands when electricity travels through wire. Expansion causes loose connections and fire hazard. Special compression fittings and wiring devices are required for aluminum wire installations. Best to avoid aluminum altogether. |
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Longer
length wires and motors/ 120-240 volt Longer runs of wire must be larger to handle same amp load. This is especially important when troubleshooting a shop inside a detached structure, or installing a water pump located several hundred feet away. Resources: Match breaker and wire size for distance Motor wire size and distance Figure volts amps watts |
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Safety test
for household electrical system Easiest way to see if there are electrical problems is the heat test All appliances, computers, TVs, AC etc put off heat. But breakers, extension cords, wires, outlets, switches and timers should not be warm. |
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All
electrical boxes, including outlets and switches must have cover plate
Stop sparks and overheating from causing fire |
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Outlet/
Switch is warm or hot Use hand to check if outlets and switches are warm. If switches and/or outlets are warm, then call electrician. Turn off power. Remove cover and inspect for loose wires. Replace switch or outlet. Monitor if new switch/outlet gets warm. Check that wire is copper and not aluminum. Add up total watts being handled by circuit and divide by 120 volts to check amp load. Each light bulb, appliance, electronic gadget has amp rating located on the device. Aluminum wiring is absolute fire hazard If wires are aluminum, then this is absolute fire hazard. Professional electrician must be called to solve problem. Aluminum wire must be replaced with copper. Special outlets-switches required for aluminum wire. Special connections required for aluminum wire. Resource: How to wire switches |
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 Circuit
breakers should not be warm or HotCheck if breakers are warm It is absolutely safe to open the main breaker access door and touch circuit breakers as illustrated on left. When finished keep the panel door closed. DO NOT unscrew and remove the cover off main panel without knowledge of safety and electric wiring experience. Even if the main breaker is turned OFF, the wires entering the main breaker are HOT. Main breaker terminals are still Hot when main breaker is turned off. Put hand on each circuit breaker. Including main breaker. There is no shock hazard touching circuit breakers when box cover is in place. Always stand on totally dry surface when touching anything electrical. For example stand on dry boards. Breakers should not be warm. Warm circuit breaker indicates problem. What does warm circuit breaker mean? It means breaker is Overheating 1) Breaker is going bad. Wiggle the breaker back and forth, and use nose and ears to listen for craclkling sound and burning. 2) Breaker is not big enough to handle Load, so amp draw is larger than breaker. 3) Breaker has been getting warm over time and is loose on the busbar. 4) There are loose wires somewhere in the circuit that are causing arcs and heating Resource2: Read main breaker stress test How to Replace circuit breaker Water heater is tripping breaker How to find ground fault |
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 Cords
should not be warm if they are used full-timeIf you are using extension cord as full time source of electricity to pump or fan, the cord should not be warm or hot If toaster oven cord gets warm when used, then that is normal If you operate the appliance full time, then upgrade to larger cord or professional appliance Vacuum cleaner cord gets hot/ Extension cord gets hot Put hand on extension cords, and household wires. Feel for warmth. If cord or wire is warm, then that indicates appliance or tool is exceeding safe-maximum. It shows the cord is too small for amp-rating of tool. Or the wire is undersized for load. A clothes dryer cord and microwave cord should NEVER be hot. Use larger size extension cord. For example, upgrade from 14 gauge to 12 gauge or upgrade more to 10 gauge. Cords frequently get warm, and that is not good. Warm indicates high load, and wated electricity.  Warm is not good, but Hot is dangerous. Cords and wires should never get HOT. If cord is hot, unplug immediately. Vacuum cleaner cords frequently get hot, because manufacturers are under-sizing the cord for the amp-draw of the appliance motor. This is typical for cheaply made consumer appliances today like toasters, blender, vacuum cleaner etc. Over time, the warm cord means motor is starving for electricity. Motor runs under-speed, causing motor to get warm, and weaken over time. Motor finally gets hot and begins to short. Cord get hot. Vacuum cleaner needs to be replaced. Space heater cords frequently get warm  This means the cord is
too small for amp-draw of space heater.Space heaters should never be operated for long hours, and should always be unplugged when not in use Space heaters come with 14 gauge wire, but safe-maximum rule says 14 gauge wire is rated for 1440 watts. 14 gauge wire is OK for space heater, but load is slightly above safe-maximum so wire can feel warm. Manufacturers make more money selling cheap products, while corporate owners complain about government codes and regulation. Then your house burns down and insurance company says you need to sue appliance manufacturer. Win-win for all except you. Always unplug appliances that are not being used Buy 12 gauge heavy-duty extension cords: 12 gauge extension cords |
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 Typical 600 watt rotary dimmer Cover plate must be installed for safety |
 Dimmers
are usually warm when ON/ but Never HotDimmer is getting hot Change light bulbs to lower wattage. Replace dimmer with new dimmer. Turn off power. Pull dimmer out and look at watt rating printed on side of dimmer. Add up total watts of all light bubs controlled by dimmer. Compare dimmer rating with actual watt rating. For example if dimmer is rated for 600 watts, then four 150 watt light bulbs will cause dimmer to get warm. Change to four 100 watt light bulbs, or buy dimmer rated for 1000 watts. Cover plate must be installed for safety Some dimmers have aluminum fins that work as heat sinks. Aluminum dissipates heat very fast. The aluminum fins can be warm, and that is normal. Aluminum fins should not be hot. Buy from my affiliate links: Dimmers at Amazon |
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Timers
should NOT get hot to touch Timer is getting hot Replace timer. Use product manual to check load rating for timer. Check watt and amp rating of Load. For example, if timer is rated for 500 watts incandescent light bulbs, but timer is connected to 600 watt TV or 1Hp pool pump, then timer will get warm or hot, and burn out. Resource: How to wire timers How to troubleshoot timers |
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 Flickering
lightsTable lamp flickering: Table lamp can have loose bulb, bulb that is going bad, loose wire, bad lamp holder, bad plug, frayed cord, loose wire in outlet, loose wire in the circuit, loose wire on breaker, bad breaker. Check bulb and lamp wire first. Try lamp in another outlet in different room, plug another lamp into same outlet, check other lights and plugs on same circuit breaker. Replace outlet, continue troubleshoot steps.  Ceiling
lights flickeringCeiling lights can have loose bulb, bulb that is going bad, loose wire in ceiling box, bad lamp holder, loose wire in the circuit (usually the Neutral located under wire nut), loose wire on breaker, bad breaker. If all lights and outlets on circuit are flickering, then problem is typically in the breaker box. If all lights in one room are affected, find the junction box that is common to all devices (usually in the ceiling), and check for loose Neutral wire(s) tied together with wire connector. Tighten loose wire on circuit breaker before sparking causes damage in breaker box. Check breaker and listen for fizzing or  crackling sound. Check if the breaker screw is
tight
against wire. Other suspects
include loose
quick connection on back of outlet or switch.
Start by opening each box and jiggling the outlet or switch.
Always put cover back on outlets,
switches etc to prevent sparks from leaving
box.Outdoor lights Outdoor lights can have loose bulb, bulb that is going bad, loose wire, corroded connection points, bad lamp holder, loose wire in the circuit (usually the Neutral located under wire nut), bad switch or timer, loose wire on breaker, bad breaker. Be careful when working on outdoor lights. Hardwired lights may not be on a GFCI outlet. Lights plugged into outlet should on GFCI. How to wire GFCI |
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 Fire inside timer caused by stranded wire Keep enclosure door closed at all times |
Sparking
wires Sparks from a loose connection usually will not damage other wires, unless the short circuit has been going on for a while... but usually a short circuit will trip breaker or the arcing will completely short out and no more electricity will flow. Always use NEW wire connectors Use silicone to seal outdoor wire connectors Do not use undersized wire Do not use stranded wire under screw places on timers, switches, outlets etc Make sure everything is properly grounded Overheated wire can catch wire and melt other wires. Resources: Match wire and breaker size How to install wire connector Grounding |
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Melted
wire Replace wire Test circuit Look for other affected wires and bad circuits Check wire and breaker size Make sure everything is properly grounded Resources How to test wires Grounding |
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Burned
switch / burned electrical part Turn power off Check condition of wires Cut back damaged wire Test wires with multimeter Check that device has same electrical rating as wire and breaker Replace part Make sure everything is properly grounded Resources: Match wire and breaker size Grounding |
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Power
safety: Never stand in water or wet surface when around electricity Never stand on bare soil Stand on dry boards Do not touch or lean into anything made of metal Use non-contact voltage tester to make sure power is OFF before making repairs  Never
assume power is OFFUse non-contact voltage tester on timer, on wire, on outlet to see if power is present. Press button on tester, if single beep then no power is present. If continuous beep then power is present. Never stand on bare ground, always stand on dry boards, do not hold or touch anything metal when working on timer or water heater that has power, tape tester leads to wood sticks, never touch wet water heater, or flooded water heater, or timer that had a short or fire without turning power OFF. Buy: Multimeters at Amazon Simple multimeter/ Test continuity or voltage Buy non-contact voltage tester at Amazon Electric testers at Amazon Shop Amazon - Industrial and scientific Shop Amazon - Industrial Electric Products |
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Whole
house surge protector/ protect appliances, wiring, timers, water
heaters etc Appliances, water heaters, timers, circuit breakers are not protected from surge Most appliances today have electronics. Few of these appliances are protected from surge Water heaters the plug into outlet are not protected from surge Homeowner insurance might have appliance exclusion. Read policy Water heater warranty does not cover surge event. Protect 120V and 240V circuits with whole house surge protector Resources How to wire whole house surge protector Intermatic IG1240RC3 whole house surge protector/ pdf |
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Main
breaker stress test Using 80% rule: Safe maximum for 125Amp main breaker is 100 Amps Safe maximum for 60 Amp main breaker is 48 amps |
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Main breaker is getting warm
Main breaker is tripping |
Calculate
PEAK amp draw. Add up PEAK amp usage using example below. Formula: Volts x amps = watts. or Watts divided by volts = amps. If appliances are gas, then they do not count. Look at labels on each item for watt rating. Add up peak usage for 120Volt. Each electric appliance has rating label. For example: microwave 1500 watts + big screen TV 500 watts + computer 300 watts + refrigerator 700 watts + lights 240 watts + dishwasher 800 watts + 1 Hp hot tub pump 750 watts + washing machine 350 watts etc = 5320 watts divided by 120 volts = 44 amps. Add up peak usage of 240Volt. For example water heater 4500 watts + heat/ac 5000 watts + clothes dryer 1800 watts + 1 Hp water well pump 750 watts + top and bottom ovens 7500 watts etc = 19550 divided by 240 volts = 81 amps. Total PEAK amp draw = 81 + 44 = 125 amps. Home may only reach PEAK once per week or once per month. Try to estimate actual peak usage that would be likely to occur. |
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 Main breaker |
PEAK
amp draw is STRESS test for main breaker Example calculation above shows peak 125 amps. If main breaker is 125 amps, then main breaker is too small to handle 125 amp PEAK load. Each time PEAK amps are used, the main breaker gets warm. Sooner or later, the main breaker has gotten warm too many times, and it stops functioning. This may take years before main stops functioning. Electricians use 80% safe maximum rule when calculating capacity of electrical devices such as circuit breaker. 80% rule also applies to switches, outlets, dimmers, timers, etc. If main breaker is rated 125 amps, then electricians multiply 125 x 80% to find maximum safe load for that breaker. 125 amps x .8 safe maximum = 100 amps So safe maximum for 125Amp main breaker is 100 Amps. If PEAK usage exceeds safe maximum for breaker, then breaker is getting warm, and is more likely to get hot and fail. |
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| Main breaker is getting warm/ Hot |
If
Main breaker is getting Hot If stress test shows that main breaker is within safe maximum, then replace main breaker. If stress test shows main is above safe maximum, then upgrade service panel to higher amp load center Resource: How to replace circuit breaker |
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| Circuit breaker is getting warm/ Hot |
If
circuit breaker is getting warm or Hot Move wire to another same-size breaker. Check if same-size breaker is also getting warm or hot. If same size also gets warm, then circuit is over amped. Call electrician. Identify all items using that breaker. Move appliances to different circuit. If same size does not get warm, then replace circuit breaker that is getting warm. Resource: How to replace circuit breaker |
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 4500 watt and 5500 watt water heaters should connect to 30 amp breaker and 10 gauge wire. |
Calculate
safe maximum for water heater circuit If residential water heater is connected to 20 amp breaker and 12 gauge wire, then the same overheating problem occurs over time. Circuit breaker will not last as long, and damage can occur to busbar. Resource: See basic water heater circuit 20 amp breaker is subject to 80% safe-maximum rule. 20 amp circuit breaker x .8 = 16 amps. So safe maximum for 20 amp breaker is 16 amps. 240Volt 4500 watt water heater draws 18.75 amps. And 5500 watt water heater draws 22.91 amps. So 20 amp breaker with 12 gauge wire is rated too small for most water heaters. Over time the breaker is getting warm, and is more likely to get hot and fail. Recommended that all water heaters be connected to 30 amp breaker and 10 gauge wire. Safe maximum for 30 amp breaker x .8 = 24 amps. Safe maximum for 10 gauge wire at 240volts is 5670 watts See chart 30 amp breaker and 10 gauge wire run cooler, with less heat loss and more efficiency. Circuit breaker and main box last longer with less chance for heat damage. Resource Figure Volts Amps Watts for water heater |
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Calculate safe maximum for water heater circuit Read label on side of water heater for element wattage. Element wattage is tank wattage. For example: If water heater has 5500 watt elements: 5500 watts divided by 240Volts = 22.91 amps 4500 watt water heater divided by 240Volts = 18.75 amps. Electricians use 80% rule for safe maximum. WH21 is rated for 25 amps x .8 = 20 amps. Calculation shows that WH21 is ok for 4500 watt water heater, but beyond safe-maximum for 5500 watt water heater. Exceeding safe maximum means WH21 will run hot and not last as long. Volts x Amps = Watts Watts divided by Volts = Amps Most residential water heaters are non-simultaneous. This means both elements are not ON at same time. Resources: Figure volts amps watts for water heater How electric water heater works How to wire thermostats If electrical device is run at-or-near maximum amp rating, the device will not last as long because of heat. Same as running a car at full throttle. Car will not last as long. In contrast, 40-amp WH40 and T104 timers are better long term investment for water heater timer. WH40 and T104 are rated for 40 amps, with safe maximum of 32 amps, so they withstand more amperage without heat loss, and will last longer. Resources: How to wire WH40 How to wire T104 Intermatic T174 timer is identical to T104, except T174 has day-skipper feature |
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| - Some gas water heaters plug into 120Volt outlet that should also be on a dedicated breaker. This is to prevent electrical interference from affecting gas control valve. This type of installation should also include surge protector to prevent surge from knocking out gas control valve electronics. | ||||
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| GFCI vs Surge protector |
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 Larger image |
Use
in-line fuse when connecting 2 different gauge wires Connect 12 gauge wire to 10 gauge wire. Illustration shows smaller 12 gauge wire connected to larger 10 gauge wire. 10 gauge wire is protected by 30 amp breaker The amp draw on 30 amp breaker is too large for 12 gauge wire. 12 gauge wire should have 20 amp breaker. Use busman fuseholder with 20 amp fuse. Fuse will protect entire length of 12 gauge wire. Connect fuse to Hot wire. Not necessary to put fuse on Neutral If the 12 gauge wire was wired for 240V, then fuse is necessary for both hot wires. Always make connections inside a box with cover Buy: Panel mount fuse holders at Amazon Buy fuseholder at Amazon Buy fuseholders at Amazonbr> Fuse blocks at Amazon 30 amp fuseholder at Amazon 20 amp fuseholder at Amazon Electrical terminals Solder guns Resource: See fuseholder Terminals |
Some fuseholders accept terminal connections, some have solder-only connections. Fuse block has screw terminals. |
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Test
outlet with circuit analyzer This is first line troubleshoot when... > When gas water heater or gas appliance plugs into outlet, the polarity and ground must be correct. > When electrical devices, and appliances do not last very long, check outlet for polarity and ground issues. > When household timers go bad quickly, or more than one timer has failed, test outlet with analyzer. Circuit analyzer Analyzer will not detect all electrical problems Analyzer will detect basic polarity and grounding issues. For example, gas water heaters that plug into outlet require correct polarity and grounding. Postage equipment and many basic office tools and computers also require correct polarity and grounding Buy: Circuit analyzers at Amazon |
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Household
outlet polarity Wires should always connect to correct blade. The wide blade is Neutral. Narrow blade is Hot. Many appliances and TVs have polarized plug. This is so Hot and Neutral can work correctly with electronics inside the device. If outlet is wired incorrectly, then appliances and timers, etc don't work as expected. Resources How to wire 240Volt outlets How to wire 3-phase outlets Wire connectors |
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Never assume electricity is OFF Turn power OFF Always stand on dry boards. Do not stand on soil or metal ladder Electricians use fiberglass ladder Do not touch or lean into anything made of metal Never stand on wet soil when working with outdoor lights, plugs, cords. Use GFCI-protected circuits for bathroom and outdoor circuits. Resources: How to wire GFCI Wire connectors |
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What is 3-phase electric: power plant to end
user Basic house wiring |
 Multimeter Test for breaks in wire/ Test for voltage Most appliance require 80% rated voltage to function correctly Buy: Multimeters at Amazon Electric testers at Amazon Resource: How to test and replace element How to test thermocouple Element tests for 120 volts How to test wire |
Safety
when testing wires: Never touch wet or previously flooded appliance. Never stand on wet surface when working on electric. Never stand on bare soil, put down dry boards. Tape tester leads to wood sticks to keep hands away from power. Use non-contact voltage tester before touching wires. Never touch or lean into any made of metal. Remove metal objects from pockets. Do not use oxygen or fuel accelerants in same room as electrical repairs Resource: Basic house wiring |
 Non-contact voltage tester Test for power without touching connectors NEVER assume power is OFF Buy: Non-contact voltage tester Amazon Electric testers at Amazon Resource: How to test electric power is off |
Twist-on wire connector assortments Do not reuse old connectors Buy Connector assortment at Amazon Connector assortment at Amazon Resource How to select and install twist-on wire connectors |
Weatherproof wire connector Connector cavity is full of silicone Built-in cover keeps silicone in place Protect from water, dust etc Buy from my affiliate links Weatherproof size 14 to 6 Amazon Weatherproof size 22 to 8 Amazon Resource How to select and install twist-on wire connectors |
Wrench to apply wire connectors Tighten connector Buy Wire connector blaster Twist connector wrenches at Amazon Resources: How to twist wireHow to select and install twist-on wire connectors |
 Push-on wire connectors in place of twist-on connectors Buy: Push on wire connectors Amazon Red 3P connector for 10-14 gauge wire Lever connectors for stranded wire at Amazon |
 Terminals Buy: Terminal kit Blue for 16-14 wire Yellow for 12-10 wire Read about terminals |
 Resource: How to install terminals |
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Buy
tools: Wire strippers at Amazon Linesman pliers Utility knife at Amazon End cutting nippers at Amazon |
Fire inside timer caused by stranded wire Keep enclosure door closed at all times Resource Timer caught fire |
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