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Why does nobody talk about how long it takes to find a single bad wire in a 30 year old panel?

Had a call last Tuesday in a building downtown where a car kept stopping between floors. Checked the controller, the door locks, the limits, everything. After 4 hours I finally found a wire that had rubbed through its insulation on a sharp edge inside the junction box. It was just barely touching ground, but only when the car moved a certain way. That one tiny spot took me longer than the whole rest of the troubleshooting combined. Has anyone else ever spent a full shift on something that simple?
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3 Comments
victor219
victor2192mo ago
Those 4 hours paid more than the fix itself, thats just job security.
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clark.iris
clark.iris2mo ago
Took me 6 hours once to find a wire that was just pinched wrong...
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henry_palmer24
Man that pinched wire thing is REAL. Was it a ground wire or a signal wire? I've seen ground wires pinch and cause all sorts of ghost issues that test fine until you put LOAD on the system. Signal wires are worse because they'll work perfectly sitting still but break connection the second the machine flexes or heats up. Did you find it by using a meter or did you just get lucky and spot the kink?
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