Why is my Power Tool Smoking and Sparking?

by: Mallory Kramer

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Date: Wed, 28 Jul 2010 Time: 4:34 AM - 0 comments

Despite the initial shock of finding sparks and smoke fuming from your power tool, these symptoms have a fairly simple fix. Because they are caused by only a few malfunctions within the tool, diagnosing a sparking or smoking one is nearly as simple as locating the site of the problem. Fortunately, this can really be only one of two places on your power tool ' the dust vents or the switch assembly. Knowing where your problem lies gives you a smooth jump-start to getting that tool back into good health.

To begin, if you experience any sparks or smoking form the ventilation points on your tool, there are just three scenarios to consider: One, your armature is bad. Two, your field is bad. And three, both your armature and field are bad. In either case, a bad field or armature is most likely the result of your having overheated, over-loaded, or in any other general sense, misused or abused the tool. You see, although many of us like to believe that our power tools are invincible, they are only designed for certain applications and with certain capacities. When pushed past their limits, chances are your tools are going to burn-up a component or two. Ultimately though, in the event of a bad field or armature, one or both of them must be replaced.

Next, if said sparks or smoke are coming from your switch assembly, there is really only one way to interpret this problem; plainly, your switch is bad. In this scenario, your switch's present state of "badness" was likely caused by a shortage in the assembly which, in turn, was most likely caused by moisture damage to the switch, or slightly less likely, by overheating in the tool. In either case the switch must be replaced.

Determinimg whether the bad-boy behind your suffering power tool is your field or armature is as simple as checking their assemblies for heat damage. Heat damage will look like burning, charring, melting or any other form or dark or colorful discoloration on the armature and field assemblies or of their wiring and wire insulation. Any heat damaged component will require fast replacement. While checking the field and armature, you may also want to look at the armature's commutator. If the bars do not form a smooth and complete circle it may cause the brushes to jump around and spark. This form of damage, however, although equally bad and equally needing of replacement, is likely not today's culprit. Also keep in mind that damage to the armature and field usually comes in pairs, i.e. if one is damaged it's likely the other is too. If you catch armature damage early, you may sometimes prevent it from spreading to the field, but if your field is damaged, your armature is pretty much out of luck.

So, in short, be good to your power tools and if you should experience smoke or sparks emitting from them, a simple parts replacement for any heat damaged component is all the doctor will order.