Documentation
Electrical
Troubleshooting
Overview

Troubleshooting Guide

This section provides systematic approaches to diagnosing and resolving electrical issues quickly and effectively, particularly under competition conditions.

🎯 Rapid Diagnosis Framework

Our troubleshooting approach prioritizes speed and accuracy through systematic elimination of potential causes.

Priority-Based Triage System

🔍 Systematic Diagnosis Procedures

Power System Troubleshooting

Complete Power Loss

Symptoms: No robot response, no LED indicators, complete electrical silence

Diagnosis Steps:

  1. Battery Voltage Check

    Expected: >11.5V under no load
Tools: Digital multimeter
Test Points: Battery terminals
Red Flag: <11.0V indicates battery failure

  2. Main Breaker Verification

    Check: Physical position (ON/OFF)
Test: Continuity across breaker
Look For: Visible damage, burning, corrosion
Action: Cycle breaker if necessary

  3. SB Connector Inspection

    Visual: Connector engagement and condition
Physical: Push/pull test for security
Electrical: Voltage at robot side of connector
Clean: Remove oxidation/corrosion if present

Partial Power Loss

Symptoms: Some systems work, others don't, intermittent operation

Isolation Strategy:

Step 1: Identify affected circuits
Step 2: Check individual fuses/breakers
Step 3: Measure voltage at load end
Step 4: Check connection security
Step 5: Measure current draw

Common Causes & Solutions:

  • Blown Fuse: Replace with same rating, investigate cause
  • Loose Connection: Re-torque to specification, apply thread locker
  • Wire Damage: Inspect for pinch points, chafing, cuts
  • Overload: Check current draw, compare to fuse rating

Brownout Conditions

Symptoms: Intermittent resets, performance degradation, voltage warnings

Investigation Process:

  1. Battery Load Test
    • Apply 200A load for 10 seconds
    • Voltage should remain above 10.5V
    • If fails, replace battery immediately
  2. Connection Resistance Check
    • Measure voltage drop under load
    • Should be less than 0.5V total from battery to PDH
    • Clean and retorque high-resistance connections
  3. Load Analysis
    • Monitor current draw during operation
    • Compare to fuse ratings and wire capacity
    • Identify unexpectedly high current draws

⚡ Emergency Repair Procedures

Time-Critical Situations (Under 15 Minutes)

Power System Emergency Repairs

Battery Connection Failure

Quick Fix Options:

Option 1: SB Connector Cleaning
- Disconnect battery immediately
- Clean contacts with fine sandpaper/emery cloth
- Apply contact cleaner if available
- Reassemble with firm engagement

Option 2: Bypass Connection
- Use jumper cables with ring terminals
- Connect directly to breaker terminals
- Secure cables to prevent shorts
- Label as temporary repair

Option 3: Connector Replacement
- Cut damaged connector from wire
- Strip wire and install ring terminals
- Connect directly to breaker or PDH
- Insulate connection thoroughly

Fuse/Breaker Failure

Immediate Actions:

Step 1: Identify Failed Protection
- Visual inspection for blown fuse
- Continuity test if time permits
- Check for signs of overheating

Step 2: Replace Protection Device
- Use identical rating replacement
- If unavailable, temporarily use next lower rating
- Document temporary change

Step 3: Address Root Cause
- Check for short circuits
- Verify load current within limits
- Inspect wiring for damage

PDH Emergency Issues

Critical Procedures:

  • Total PDH Failure: Bypass with fused connections directly from battery
  • Individual Channel Failure: Redistribute loads to working channels
  • Communication Loss: Switch to PWM control if CAN fails

📊 Diagnostic Tools and Equipment

Essential Troubleshooting Tools

Software Diagnostic Tools

RoboRIO Diagnostics:

  • DriverStation Log Viewer: System messages and error codes
  • RoboRIO Web Interface: Real-time system monitoring
  • Phoenix Tuner: Motor controller configuration and diagnostics
  • REV Hardware Client: REV device configuration and monitoring

Network Analysis Tools:

  • Wireshark: Network packet analysis and troubleshooting
  • Network Scanner: Device discovery and connectivity testing
  • Bandwidth Monitor: Network utilization and performance
  • Ping/Traceroute: Basic connectivity verification

🚨 Emergency Response Procedures

Safety-First Protocols

Electrical Emergency Response:

  1. Immediate Isolation: Disconnect power source
  2. Area Clearance: Remove personnel from danger zone
  3. Assessment: Evaluate extent of problem and safety risks
  4. Communication: Notify appropriate personnel and officials
  5. Documentation: Record incident details for investigation

Fire/Smoke Protocols:

  1. Power Isolation: Main breaker OFF immediately
  2. Fire Suppression: Use appropriate extinguisher (Class C electrical)
  3. Evacuation: Clear area of all personnel
  4. Emergency Services: Call professional help if needed
  5. Investigation: Determine root cause before re-energizing

Recovery Procedures

System Restart Protocol:

Step 1: Complete visual inspection
Step 2: Verify all connections secure
Step 3: Check fuse/breaker continuity
Step 4: Measure battery voltage
Step 5: Enable power in stages
Step 6: Monitor for normal operation
Step 7: Document any anomalies

Post-Emergency Checklist:

  • All safety systems functional
  • No signs of damage or overheating
  • Documentation updated with repairs
  • Team briefed on incident and resolution
  • Spare parts inventory replenished
  • Lessons learned incorporated into procedures
⚠️

Safety Priority: No competition is worth risking personal safety. If there's any doubt about electrical safety, seek expert assistance before proceeding.

💡

Documentation Importance: All troubleshooting activities, temporary repairs, and emergency procedures must be thoroughly documented for safety, compliance, and continuous improvement.

FRC ComplianceDiagnosis Flowcharts