How To Find Burnt Resistor Value PDF

How To Find Burnt Resistor Value Even Without A Schematic Diagram
How to Find Burnt Resistor Value Even Without a Schematic

Diagram
By Jestine Yong
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©Jestine Yong – ElectronicRepairGuide.com

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TABLE OF CONTENTS
1. ACKNOWLEDGEMENTS……………………………………….….……… 4
2. WHAT IS A RESISTOR?…………………….……………….……….…….. 5
3. TYPE OF RESISTORS…………………....…………………..……………... 6
4. POWER RATING OF RESISTOR…………………………...……………… 11
5. VOLTAGE RATING OF RESISTOR………………......……………………. 11
6. RESISTOR COLOR CODE………………………………....……………….. 12
7. TYPICAL EXAMPLES ON HOW TO CALCULATE RESISTOR COLOR

CODE AND TOLERANCES...……………………………………………… 14
8. CODES INDICATING VALUES AND TOLERANCES..………………….. 18
9. SURFACE MOUNT RESISTOR CODING…………………………………. 19
10. RESISTORS IN SERIES AND IN PARALLEL……………………………... 20
11. WHY CONNECTING RESISTOR IN SERIES OR PARALLEL IS

IMPORTANT?………………………………………..……………………… 22
12. APPLICATIONS OF RESISTORS IN ELECTRONIC CIRCUITS…………. 23
13. HOW RESISTOR FAILS?………………………………………….………... 24
14. TESTING OF RESISTORS…………………………………………………... 25
15. RESISTOR REPLACEMENT………………………………………………... 27
16. TYPICAL RESISTORS VALUE…………………………………………….. 28
17. LET’S GET STARTED – CONSTRUCTION OF A FILM TYPE

RESISTORS………………………………………………………………….. 29
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18. TOOLS AND TEST EQUIPMENT REQUIRED TO DETERMINE THE

VALUE OF A BURNT RESISTOR……………………….…….…………… 31
19. STEP-BY-STEP GUIDE……………………………………………………... 33
20. THE RIGHT METHOD TO CHECK THE VALUE OF A RESISTOR

WITH PROTECTIVE LAYER REMOVED…………………………………. 35
21. TYPICAL EXAMPLES OF BURNT AREA IN A RESISTOR AND HOW

TO DETERMINE THE VALUE……………………………….…………….. 39
22. USING COMPARISON METHOD……………………………….…………. 44
23. TRUE CASE HISTORIES…………………………………………………… 45
24. CONCLUSION……………………………………………………………….. 48
APPENDIX
ABOUT THE AUTHOR…..…………………………………………………. 49
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Acknowledgements
Many professionals have contributed to this book and I gratefully acknowledge their tremendous
effort in making this work so comprehensive. It would have been an impossible job for just one
person. I thank all who contributed, directly or indirectly.
I give special thanks to the following: Goh Wei Eng, Michelle Lee, Wong Wai Mun and Tan May
Lee.
I also wish to thank my partner William Hor of Noahtec.com for help and encouragement
throughout the years.
Very special thanks to Timothy Wong who edited the manuscript.
To Michelle Tan, my wife, I extend my thanks. Without her loving support and encouragement, this
book would still have been possible, but not nearly worth the effort.
Limit of Liability / Disclaimer of Warranty:
The authors and publisher of this book and the accompanying materials have used their best
efforts in preparing this program. The authors and publisher make no representation or
warranties with respect to the accuracy, applicability, fitness, or completeness of the
contents of this program. They disclaim any warranties (expressed or implied),
merchantability, or fitness for any particular purpose. The reader is expressly warned to
consider and adapt all safety precautions that might be indicated by the activities here in and
to avoid all potential hazards. By following the instructions contained herein, the reader
willingly assumes all risks in connection with such instructions. The authors and publisher
shall in no event be held liable for any loss or other damages, including but not limited to
special, incidental, consequential, or other damages. As always, the advice of a competent
legal, tax, accounting or other professional should be sought.
This manual contains material protected under International and Federal Copyright Laws
and Treaties. No parts of this manual shall be reproduced or transmitted by any means,
electronic, mechanical, photocopying and recording or otherwise. Any unauthorized use of
this material is prohibited. All product illustration, product names and logo are trademark of
their respective manufacturers.
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What Is A Resistor?
A resistor is a passive electronic component that opposes the flow of electrical current through it.
The word resistance means opposition to some action. In electricity, resistance means the
opposition to the flow of current. Resistance is measured in ohms using the Greek symbol omega
(Ω). Resistance is also expressed in kilo-ohms, milli-ohms etc. With 1000Ω = 1 kilo ohms,
1,000,000Ω = 1 mega ohms.
The two sets of standard symbols for representing resistors in electronic circuits are given in Fig 1
(a) and (b).
(a)
Fixed Resistors Variable Resistors Tapped Resistors
(b)
Fig 1: Symbols for resistors
The two main characteristics of resistor are its resistance R in ohms and its power rating in watts,
W. Resistors are available in a very wide range of R value from a fraction of an ohm to many mega
ohms. The value of the resistance can be measured by an ohmmeter or multimeter.
Page 5

Types Of Resistors
There are two main classifications of resistors: fixed and variable. Fixed resistors have only one
ohmic value, and unless the resistor is defective, it always has the same ohmic value. However, the
ohmic value of a variable resistor can change, or vary.
Fixed Resistors
a) Carbon Composition Resistors

The resistance element in a carbon composition resistor is a
compress slug of a finely ground mixture of carbon and silica.
It is much harder for electrons to press through carbon than
copper, so the flow of current is limited. The significant
advantages of composition resistor include:
! Extremely small inductance and capacitance
! Do not fail catastrophically
! Can withstand higher voltages than the film resistors of
standard configuration.
Carbon composition resistors are rarely used in modern Fig 2: Carbon

electronics because they are large, less stable, comparatively composition
noisier and they lack the precision needed to support Resistors
contemporary circuits. The carbon composition resistor has
been replaced by the film type resistors.
b) Film Type Resistors

There are two kinds: the carbon-film and metal-film resistors.
i. Carbon Film Resistors

In carbon film resistors, the resistive element is a thin
layer of carbon on the surface of a ceramic or glass rod
or tube. Carbon-film resistors have largely replaced
carbon-composition resistors in most circuits requiring
through-hole resistors.
The advantages of the carbon film resistors are:
# They are more accurate than carbon-composition
devices because films are applied with more precision Fig 3: Carbon-
and control.
Film Resistors
# They have better tolerances specification
(+ 5% to + 0.5%)
# They have a wide resistance range (0.1Ω to 100MΩ)
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The disadvantages of carbon film resistors are:

# They are prone to catastrophic failure. The thin fragile
film has no ability to withstand electrical overloads.
# They have comparatively higher inductances.
ii. Metal film Resistors
These are similar to carbon-film resistors in construction
except that the film is of a metal alloy or a metal-oxide.
These have the advantage of both carbon film and precision
wire-wound resistors without having the disadvantages of Fig 4: Metal-Film
either. Resistors
c) Wire-Wound Resistors
Sometimes it is necessary for a fixed resistor to dissipate more power in a circuit than a
carbon resistor is able to handle. In these cases, wire-wound resistor is called for. A wire-
wound resistor, which can run much hotter than a carbon resistor is fabricated by winding
one or more than one layers of a high resistance wire. The fragile windings are protected
against mechanical and environment hazards by dipped, sprayed, molded or rigid covers of
high temperature silicone, inorganic cement, vitreous enamel, aluminum housed, plastic or
ceramic materials. Wire-wound resistors are preferred over carbon composition resistors in
low resistance, low noise applications. Since they are generally for high-current applications
with low resistance and appreciable power, wire-wound resistors are available in wattage
ratings from 5W up to 100W or more. The resistance can be less than 1Ω up to several
thousand ohms. Wire-wound resistors do not have a color code, the value in ohms is printed
on its body.
a) Ceramic Body b) Silicon Coated
c) Vitreous Enamel d) Aluminum Housed
Fig 5: Types of wire-wound resistors
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d) Fusible Resistors
Flame proof or fusible resistors are designed to meet the safety
requirements of power supply, measurement, control and audio/
video equipment where protection against overload is required.
It serves the dual functions of a fuse and resistor to limit the
current. The resistors became open circuit within a certain range
if it overloads without the risk of fire. They are often designated
‘FR’. They look like power resistor but coated with blue or gray
flame retardant lacquer that resist to all cleaning solvents. Fig 6: Fusible
They also can come in the form of rectangular ceramic blocks. Flame Proof
If the fusible resistor developed an open circuit or blown, you Resistors
probably have shorted semiconductors that will need to be replaced
as well. A shorted Horizontal Output Transistor (HOT) or diode may
cause the resistor to go open-circuit especially in the Monitor or TV
circuit. The value of a fusible resistor may be a fraction of an ohm but
can be larger. For testing only, a normal resistor may be substituted but
the proper replacement (identical rating) must be installed before
returning the equipment to customer. A wrong replacement may increase
the risk of fire.
e) Resistor Networks
This is a special type of resistor where the resistors are manufactured together in a single
package called single inline package (SIP), or in a package with two rows of inline pins
called a DIP, for dual inline package. Packages contain three, four or five individual
resistors, or common configurations of four, five, seven, eight or nine resistors of identical
value. Their use greatly simplifies printed circuit layout, especially in logic circuits where
many pull up or pull down resistors are required. Other advantages include considerable
savings in space and assembly time.
a) Single Inline Package (SIP) b) Dual Inline Package (DIP)
Fig 7: Resistor Networks
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Variable Resistors
Variable resistors can be wire-wound or the carbon type. The resistance value of variable resistors,
as the name suggests, can be varied over the specified resistance range. The variable resistor has a
movable contact arm called a wiper that can travel along the resistive material from one end of the
resistor to the other. The wiper can therefore contact, or tap, any value of resistance from zero ohms
up to the maximum value of the variable resistors. The ohmic value of a variable resistor is the
maximum resistance from end to end. Thus, a 10k variable resistor measures 10,000ohms from one
end to the other. The wiper can tap any value between 0 and 10,000Ω. Variable resistors can be
classified as:
a) Potentiometers or Pots
Potentiometers are the most common form of variable resistor in electronic circuits. A
potentiometer or called pot in short, is made of either carbon composition material or
resistive wire with a connection at each end. Specifically a potentiometer is designed for
frequent and sometimes continuous movement of the adjustable terminal. There are two
typical types of potentiometer: single turn potentiometer, where wiper is turned clockwise or
counterclockwise using a rotating metal shaft, and slider potentiometer, where the wiper is
moved back and forth in a straight line.
a) Single Turn Potentiometer b) Slider Potentiometer
Fig 8: Typical Potentiometers
b) Trimmers or Presets
They are designed for infrequent adjustment or calibration of electronic circuits. These are
normally varied and then set for best performance. Use an insulated screwdriver or TV
alignment tool to adjust these.
Fig 9: Trimmers or Presets
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c) Rheostats
Rheostat is a variable resistance of higher wattage and often used to control relatively large
values of current in low resistance circuits for ac power applications. Rheostat has two
terminals and connected in series with a load. Rheostats may be either wire-wound or
carbon.
Fig 10: Wire-wound Rheostat
Page 10

Power Rating of Resistors

A resistor should have a wattage rating high enough to dissipate the power produced by the current
flowing through the resistance, without becoming too hot. However, if a resistor is forced to exceed
its power rating, it cannot shed heat fast enough to maintain a stable temperature. Ultimately, the
resistor will overheat and burn out.
The power rating is a physical property that depends on the resistor’s construction, especially its
physical size. For a given type of resistor:
a) The larger it is the more power it can handle.
b) Higher-wattage resistors can operate at higher temperatures.
c) Wire-wound resistors are physically larger with higher wattage ratings than carbon resistors.
The majority of resistors in consumer electronics are 1/8W, 1/4W, 1/2W, 1W and 2W. As long as
the power being dissipated by a resistor is less than it’s rating, the resistor should perform as
expected and last indefinitely.
Voltage Rating of Resistors

I believe many technicians know that capacitors have voltage ratings and resistors have power
ratings. But do you know that a resistor also has a voltage rating? This rating gives the highest
voltage that may be applied across the resistor without arcing between the end caps or internal
leads. A resistor with a higher power rating allows a higher voltage rating. In the cases of general-
purpose carbon composition resistors, the maximum voltage rating is 150V (for 1/8W), 250V (for
1/4W), 350V (for 1/2W), 500V (for 1W) and 750V (for 2W). For general-purpose carbon film
resistors, the values are more or less identical.
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Resistor Color Code

Fixed resistors are marked in several ways. These are:
i. Color coding
ii. Straight numerical value
iii. Certain numerical codes that can be easily translated.
Because carbon resistors are small physically, they are color coded to mark their R-value in ohms.
In memorizing the colors, note that the darkest colors, black and brown, are for the lowest numbers,
zero and one, through lighter colors to white for nine. Reading from left to right, the first band close
to the edge gives the first digit in the numerical value of R. The next band marks the second digit.
The third band is the decimal multiplier, which gives the number of zeros after the two digits. As
for the five color bands resistors, the fourth band is the decimal multiplier.
Technicians must know this code.
Table 1 and 2 shows the color code and their meanings.
Colour Digit Multiplier Tolerance

Black 0 1 -
Brown 1 10 -
Red 2 100 -
First Band
(First Digit) Orange 3 1000 -
Second Band
(Second digit) Yellow 4 10000 -
Third Band
(Multiplier)
Green 5 100000 -
Fourth Band Blue 6 1000000 -

(Tolerance)
Violet 7 10000000 -
Grey 8 - -
White 9 - -
Gold - 0.1 +5%
Silver - 0.01 +10%
No colour - - +20%
TABLE 1- The four colors band of resistor and their meanings.
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Tolerance Code
Black -
First Band
(First Digit) Brown +1%
Red +2%
Second Band Orange -
(Second digit) Yellow -
Third Band Green +0.5%
(Third digit) Blue +0.25%
Violet +0.1%
Fourth Band
(Multiplier) Grey +0.05%
White -
Fifth Band Gold +5%
(Tolerance) Silver +10%
TABLE 2- The five colors band of resistor and their meanings.
Page 13

Typical Example On How To Calculate The Resistor Color

Codes And Tolerances
Example 1:
red violet red gold
The first band is red for 2 and the next band is violet for 7. The red multiplier in the third band
means an additional two zeroes to 27. The result can be illustrated as follows:
red violet red
2 7 x 100 = 2700
Therefore, this R-value is 2700Ω with tolerance ± 5% (gold).

The value of a resistance has a tolerance (given in percentage) within which the value may vary due
to imperfections in manufacturing process. It may be anything from 1% or even less (for critical
applications) to 10 or 20% (for normal electronic circuits). Tolerance is marked in the color code by
the last band of color (as given in the example).
For instance, the 2700Ω resistor with ± 5 percent tolerance can have a resistance of 5 percent above
or below the coded value.
This R, therefore, is between 2565Ω and 2835Ω. The calculations are as follows:
5 percent of 2700 is 0.05 x 2700 = 135
For +5 percent, the value is

2700 + 135 = 2835 Ω
For -5 percent, the value is

2700 - 135 = 2565 Ω
A 10Ω resistor with + 5 percent tolerance will have the value range between 9.5Ω to 10.5Ω. Say if
you measure this resistor with a digital multimeter and it showed 10.3Ω or 9.8Ω, the resistor is still
within the tolerance range and said to be good. However if this resistor measure showed 10.9Ω or
8.9Ω it is considered out of the tolerance range and it should be replaced. It’s a good idea to check
the actual resistance with your multimeter before you install the part.
Page 14

Example 2:
green blue orange silver
green blue orange
5 6 x 1000 = 56000Ω
Therefore, the R-value is 56000Ω or 56kΩ with tolerance ± 10% (silver).
Example 3:
orange orange black gold
Example 3 illustrates that black (third band) just mean that “do not add zeroes to the first two digit”.
Since this resistor has orange, orange, and black band, the R-value is 33Ω with tolerance ±5%
(gold).
Example 4:
brown grey black silver
18 x 1 = 18Ω
The R-value is 18Ω with tolerance ±10% (silver).
Example 5:
brown green gold gold
For these values, the third band is gold, indicating a fractional decimal multiplier. When the third
band is gold, multiply the first two digits by 0.1. The R-value is
brown green gold gold
1 5 x 0.1 = 1.5Ω ±5%
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Example 6:
yellow violet gold silver
47 x 0.1 = 4.7Ω ±10%
Example 7:
red red silver gold
For these values, the third band is silver. When the third band is silver, multiply the first two digits
by 0.01. The R-value is
red red silver gold
2 2 x 0.01 = 0.22Ω ± 5%
Example 8:
blue grey silver silver
68 x 0.01 = 0.68Ω ±10%
Example 9:
green brown black red brown
The first band is green for 5, the next band is brown for 1 and the black for 0. The red multiplier in
the fourth band means add two zeroes to 510. The result can be illustrated as follows:
510 X 100 = 51000
Therefore, this R-value is 51000Ω or 51kΩ with tolerance ± 1% (brown)
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Example 10:
yellow orange blue orange red
yellow orange blue orange
4 3 6 x 1000 = 436000
Therefore, this R-value is 436000Ω or 436kΩ with tolerance ± 2%.
Page 17

Codes Indicating Values And Tolerances

For some resistors like the wire-wound type, the value of resistance is indicated on the body of the
resistor in digit-letter code. The letter placed after the digit indicates the multiplier and position of
the decimal. R indicates 100 multiplier, K indicates 10³ and M indicates 106. Table 3 illustrates the
digit-letter code system.
Table 3: Value of resistors in digit-letter code

Code Value
R82 .82Ω
15R2 15.2Ω
100R 100Ω
10K 10KΩ
2K7 2.7KΩ
2M2 2.2MΩ
Tolerance indicating letter is the last letter in digit-letter code.

Letter F indicates 1% tolerance; G, 2%: H, 3%: I, 4%: J, 5%: K, 10% and M, 20%.
For example, a resistance of 1.2kΩ 20% tolerance would be indicated as 1K2M, and 100Ω 5%
tolerance as 100RJ.
Page 18

Surface Mount Resistor Coding

Color-coded resistors are rapidly being replaced by surface mount resistors (SMD chip resistor). As
with carbon-film resistor, surface mount resistors are formed by depositing a layer of carbon film
into a thin ceramic substrate. Metal tabs are attached at both ends of the wafer. Surface mount
resistors are soldered directly on the top or bottom sides of a printed circuit board instead of using
leads to penetrate the PC board. Surface mount resistors are used extensively in computers and
printers. Surface mount resistors are far too small for clear color-coding (only a few square
millimeters in area), yet they offer very tight tolerances. The identification value of the surface
mount resistor is found on top, and is indicated with three numbers. The first number is the single
digit, number two is the second digit, and the third number, the multiplier (Fig 11). Notice a solid
SMD has “000” marked on top of part. Do not mistake this for a shorted component. It is actually a
jumper.
Standard Chip Resistor Code Example
Fig 11: The standard chips code with numbers on top of SMD resistor and example
Page 19

Resistors in Series and in Parallel

Resistors in Series
If R1, R2, R3, etc, are the resistors connected in series as shown in Fig 12, the total resistance R is
equal to the sum of the individual resistances, as given by
R = R1 + R2 + R3 +……
R1 R2 R3
Fig 12: Resistors in Series
Example 1: What is the total resistance of the series circuit illustrated below?
5Ω 10Ω 15Ω
R1 R2 R3
R = R1 + R2 + R3
R = 5Ω + 10Ω + 15Ω
R = 30Ω
Example 2: What is the total resistance of the series circuit illustrated below?
10Ω 22Ω
R1 R2
R = R1 + R2
R = 10Ω + 22Ω
R = 32Ω
Page 20

Resistors in Parallel
When two or more resistors are connected in parallel as shown in Fig 13, the total resistance R is
given
1 = 1 + 1 + 1 + …….
R R1 R2 R3
Fig 13: Resistor in Parallel

When two different value resistances say 20 Ω and 10 Ω are connected in parallel, the net resistance
is equal to the product of two resistances divided by their sum.
20 Ω
R1
10 Ω
R2
Total resistance RT = R1 x R2 = 20 x 10 = 200 = 6.66 ohms

R1 + R2 20 + 10 30
20 Ω
R1
20Ω
R2
When equal value resistances are connected in parallel, the total resistance is equal to the value of
any one of the resistances divided by the number of resistance in parallel.
The total resistance is: 20 = 10 ohms
2
Voltage across each parallel resistance remains the same, but current in each resistance would be
different depending upon the value of the resistance.
Page 21

Why Connecting Resistor In Series Or Parallel Is

Important?
Imagine this scenario, if you came across an open circuit 36 ohm resistor and you could not find
this value in the market or your customer need the equipment by tomorrow morning and the resistor
is temporary out of stock from your spare part department, what would you do? The answer is to
use the series or parallel resistance formula to solve your problem. In your case, you can always use
two 18Ω resistor connected in series.
18Ω 18Ω
RT = R1 + R2
RT = 18Ω + 18Ω
RT = 36Ω
Or you can use a 24Ω and a 12Ω resistor connected in series
24Ω 12Ω
RT = R1 + R2
RT = 24Ω + 12Ω
RT = 36Ω
If you need a 50Ω resistor, you can connect two 100Ω resistor in parallel.
100Ω
100Ω
RT = R1 x R2 = 100 x 100 = 10000 = 50Ω

R1 + R2 100 + 100 200
In the field of servicing, time is money. The lesser amount of time you use on one job, the more
number of jobs you can do and hence the more you can earn. For this you must understand the
series and parallel connection of a resistor. It is not possible to run to the market every time to get a
correct replacement of resistor, it is time-consuming, and it is also not economical. It kills the
efficiency and presence of mind, and steals precious time.
Page 22

Applications Of Resistors In Electronic Circuits

Resistors are used in electronic circuits for various functions. These are described below:
! Voltage Drop – When current I flows through a resistor, voltage drop, equaled to
I X R, takes place across the resistor.
! Current Limiter – In zener diodes and diodes, a resistance is used in series to limit the
current to a safe value in order to save the diodes from burning.
! Bleeder Resistor In Power Supplies – It is used in high-voltage power supplies. The

capacitor of the power supply is charged to
peak voltage and when the load is off, high voltage
across the capacitor may dangerously leak through
the body of service technician during servicing. To
counter this problem, a resistance of high value is
connected across the capacitor in power supplies.
! Potential Divider – When voltage is applied across two or more resistors in a series,
voltage divides itself amongst the resistors so that voltage across each
resistor = series current X value of resistor. Such voltage dividers are used
for giving fixed bias in transistor circuits, giving desired voltage to the
various electrodes of CRT, etc.
! Resistive Matrix – PA amplifier mixers use fader resistors to isolate different microphones.
Resistive matrix is also used to obtain luminance signal in color TV
transmitters.
! Feedback Resistor – Negative feedback is often given by a resistive network from

output to input in amplifiers.
! Q-reduction (Damping) – Q of a resonant circuit is reduced by connecting a resistance

in parallel with the circuit. This is sometimes required to
flatten the resonance curve.
! Receiver Controls – Potentiometers are used in receivers for controlling various

parameters, like gain, brightness, contrast, volume, etc.
In conjunction with capacitors, a resistor is used for many other functions some of which are
mentioned below:
1. Decoupling circuits
2. Wave shaping circuits
3. Time base circuits
4. Ripple smoothing filter
5. Equalization circuits
6. Bass and treble controls
Page 23

How Resistors Fail?

The most common trouble in resistor is either it increases in value, or it opens up altogether. Small
resistors are physically fragile; mechanical abuse and corrosion in metal resistor can cause a lead to
pull away from the carbon material in the center of the resistor body. Overheating can also make a
resistor increase in value or open.
A faulty resistor may appear only slightly discolored, or it may look burnt and cracked, depending
upon the severity and duration of its overheating. Severe overheating can also burn a printed circuit
board. In nearly all cases of overheating, the resistor, itself is not at fault; rather, some other
components, such as a transistor, diode or capacitor, have either shorted out or have become leaky
due to higher supply voltage. This causes too much current to flow through the resistor, which then
overheats. Generally, you will want to find and correct the cause of overheating first, and then
replace the resistor.
Sometimes a resistor becomes electrically noisy and unstable. If you measured with an ohmmeter it
will show a right value, but in an actual circuit with current flowing through it, the resistance
fluctuates. If the resistance changes rapidly, the resistor is said to be noisy. In a monitor circuit, a
noisy resistor can cause picture instability. However, noisy resistors are very rare.
Unstable and noisy resistors can be very hard to locate. It usually changes value slowly as it heats
up. It causes the affected circuit to function intermittently. The affected circuit often works correctly
for a while, but after the unit heats up, some problems appear. In order to solve this problem, a can
of freeze spray is used. When a heat-sensitive component gets cooled off, normal operation is
temporarily restored. Sometimes, several coats might be needed to get the suspected component to
act up. Be very careful not to use just any spray coolant. Some types can generate static charges in
the thousands of volts when they are used. Sensitive devices can be damaged by static discharges.
Spraying a hot integrated circuit (IC) could cause it to crack under thermal stress.
Page 24

Testing Of Resistors
Testing a Fixed Resistor
You can check the resistance of a resistor with a digital multimeter set to ohm’s range. Resistance is
measured in parallel across components with all circuit power off as shown in Fig 14.
Fig 14: Measuring Resistance
It may be necessary to remove at least one component lead from its circuit to prevent
interconnections with other components from causing false readings. In other words, you are
measuring only the resistor, not other components in the circuit. Place your test lead across the
component and read resistance directly from the display. An open resistor reads infinitely high
ohms. It is important not to touch the meter’s lead. There is no danger of shock, but the body
resistance acts as a parallel path that will lower the ohmmeter reading.
If you are experienced enough, you can check a resistor in circuit without soldering out the resistor
lead from the circuit. Always be aware of possible back circuits when performing in-circuit
resistance measurements. But if you connect your meter leads across a resistor in a circuit and it
measures higher than it should, then you know the resistor is either opened or has gone up in value.
Other circuit components cannot possibly increase the value of a resistor; and back circuit could
only make the resistance reading lower.
If a component measures less resistance than its rated value when checked in the circuit but normal
when measured out of the circuit, a parallel path is being measured. This parallel path could be a
junction of a transistor or a diode, or it could be that a capacitor is conducting when capacitors
usually do not conduct. This is one way to identify a leaky capacitor.
Page 25

Testing Variable Resistor

Failure among variable resistors usually takes form of intermittent connections between the wiper
blade and resistive film. Sometimes it also can be burned due to overload of currents and develop
an open circuit. Remember that film slowly wears away as the wiper moves back and forth across it.
After sometimes the overall film can wear away that which the wiper cannot make a good contact at
certain points. The poor contact can cause all types of erratic or intermittent operation.
If the intermittent connections are due to dust and debris, using an electronic oil-based contact
cleaner may help to solve the problem. But, if the problems are caused by the wearing away of the
resistive film, the only option is to replace the variable resistors.
You can check the variable resistor resistance with a digital multimeter set to ohm’s range as shown
in Fig 15.
(a) (b)
Fig 15: Testing a variable resistor with a digital multimeter
Use either one probe to touch pin 1 and 2 (Fig 15a) of variable resistor while the other probe
touching pin 3. Turn the knob clockwise and anti-clockwise to see the changing of resistance. The
meter should show a smooth reading. If the reading is erratic, service or replace the variable
resistor. Say if the variable resistor is 10kΩ the ohms value should vary from 0Ω to 10kΩ, or 10kΩ
to 0Ω as you turn the knob clockwise and anti-clockwise.
Now, using the probe that touches pin 3 short to pin 2 (Fig 15b) while the other probe connects to
pin 1, test for the result. The reading should be the same except that the ohms range instead of
starting at 0Ω should now start at 10kΩ.
Page 26

Resistor Replacement
Sometimes, it can be more trouble to find parts than it is to identify the problem in the first place. In
some cases, you must locate an exact replacement for the bad parts; sometimes, you can get away
with a “near match”.
A replacement resistor should have the same resistive value and tolerance (or better) as the original.
It is acceptable to replace a resistor with one having a higher wattage rating. For example, suppose
you measure a 1/8W resistor in a TV circuit and find it to be 870 ohms, when it should be 330
ohms. Go ahead and replace this with a 330Ω 1/4W or even 1/2W resistor. Resistors with a wattage
rating of 1/8W can be hard to find or buy in small quantities, but are available from larger electronic
suppliers and mail order companies. It’s a good idea to check the actual resistance with your
multimeter before you install the part. Finally, consider the physical size of the resistor. Be sure the
replacement will fit into your equipment.
Note: Always use a replacement resistor with a power rating that is equal to or
greater than the original.
Page 27

Typical Resistors Value

1) 0.1 Ω 28) 4.3 Ω 55) 100 Ω 82) 4.3 kΩ 109) 100 kΩ 136) 4.3 MΩ
2) 0.12 Ω 29) 4.7 Ω 56) 120 Ω 83) 4.7 kΩ 110) 120 kΩ 137) 4.7 MΩ
3) 0.15 Ω 30) 5.1 Ω 57) 150 Ω 84) 5.1 kΩ 111) 150 kΩ 138) 5.1 MΩ
4) 0.18 Ω 31) 5.6 Ω 58) 180 Ω 85) 5.6 kΩ 112) 180 kΩ 139) 5.6 MΩ
5) 0.22 Ω 32) 6.2 Ω 59) 220 Ω 86) 6.2 kΩ 113) 220 kΩ 140) 6.2 MΩ
6) 0.24 Ω 33) 6.8 Ω 60) 240 Ω 87) 6.8 kΩ 114) 240 kΩ 141) 6.8 MΩ
7) 0.27 Ω 34) 7.5 Ω 61) 270 Ω 88) 7.5 kΩ 115) 270 kΩ 142) 7.5 MΩ
8) 0.33 Ω 35) 8.2 Ω 62) 330 Ω 89) 8.2 kΩ 116) 330 kΩ 143) 8.2 MΩ
9) 0.39 Ω 36) 9.1 Ω 63) 390 Ω 90) 9.1 kΩ 117) 390 kΩ 144) 9.1 MΩ
10) 0.43 Ω 37) 10 Ω 64) 430 Ω 91) 10 kΩ 118) 430 kΩ 145) 10 MΩ
11) 0.47 Ω 38) 12 Ω 65) 470 Ω 92) 12 kΩ 119) 470 kΩ 146) 12 MΩ
12) 0.51 Ω 39) 15 Ω 66) 510 Ω 93) 15 kΩ 120) 510 kΩ 147) 15 MΩ
13) 0.56 Ω 40) 18 Ω 67) 560 Ω 94) 18 kΩ 121) 560 kΩ 148) 18 MΩ
14) 0.62 Ω 41) 22 Ω 68) 620 Ω 95) 22 kΩ 122) 620 kΩ 149) 22 MΩ
15) 0.68 Ω 42) 24 Ω 69) 680 Ω 96) 24 kΩ 123) 680 kΩ 150) 24 MΩ
16) 0.75 Ω 43) 27 Ω 70) 750 Ω 97) 27 kΩ 124) 750 kΩ 151) 27 MΩ
17) 0.82 Ω 44) 33 Ω 71) 820 Ω 98) 33 kΩ 125) 820 kΩ 152) 33 MΩ
18) 0.91 Ω 45) 39 Ω 72) 910 Ω 99) 39 kΩ 126) 910 kΩ 153) 39 MΩ
19) 1 Ω 46) 43 Ω 73) 1 kΩ 100) 43 kΩ 127) 1 MΩ 154) 43 MΩ
20) 1.2 Ω 47) 47 Ω 74) 1.2 kΩ 101) 47 kΩ 128) 1.2 MΩ 155) 47 MΩ
21) 1.5 Ω 48) 51 Ω 75) 1.5 kΩ 102) 51 kΩ 129) 1.5 MΩ 156) 51 MΩ
22) 1.8 Ω 49) 56 Ω 76) 1.8 kΩ 103) 56 kΩ 130) 1.8 MΩ 157) 56 MΩ
23) 2.2 Ω 50) 62 Ω 77) 2.2 kΩ 104) 62 kΩ 131) 2.2 MΩ 158) 62 MΩ
24) 2.4 Ω 51) 68 Ω 78) 2.4 kΩ 105) 68 kΩ 132) 2.4 MΩ 159) 68 MΩ
25) 2.7 Ω 52) 75 Ω 79) 2.7 kΩ 106) 75 kΩ 133) 2.7 MΩ 160) 75 MΩ
26) 3.3 Ω 53) 82 Ω 80) 3.3 kΩ 107) 82 kΩ 134) 3.3 MΩ 161) 82 MΩ
27) 3.9 Ω 54) 91 Ω 81) 3.9 kΩ 108) 91 kΩ 135) 3.9 MΩ 162) 91 MΩ
Page 28

Let’s Get Started

Construction Of A Film–Type Resistors
In carbon-film resistors, the resistive element is a thin layer of carbon on the surface of a ceramic or
glass rod or tube. Metal film resistors are similar to carbon-film resistors in construction except that
the film is of a metal alloy or a metal-oxide. The thickness of these coating (carbon or metal film)
affects the amount of resistance – thicker coatings yield lower levels of resistance, and vice versa.
Metal caps on both ends provide the electrical connections as shown on Fig 16.
Fig 16: Cross-sectional view of a film-type resistor
A spiral groove is cut with a lathe or laser beam through the deposit to produce a spiral-wound
resistor, which is then covered or encapsulated in a hard epoxy material as shown in Fig 17.
Fig 17: Construction of film-type resistor
Page 29

Tips: View the resistor where the encapsulating material has been removed to see how many stripes
the spiral groove produced. In Fig 17, the spiral groove produced three stripes. Some resistors have
half, one, two, three and up to seven or more stripes. Generally, the more stripes a resistor has,
the higher resistance it will be. The fewer stripes it has, the lower resistance it will be as shown
in Fig 18.
a) ½ stripe (0.1Ω) b) 1 stripe (1Ω) c) 2 stripes (10 Ω)
d) 3 stripes (100Ω) e) 4 stripes (1KΩ) f) 5 stripes (10KΩ)
g) 6 stripes (100KΩ)
Fig 18: Counting total number of stripes of a resistor
Note: The construction of wire wound resistor is quite similar to film type resistor except
that the protective layer is covered by ceramic or silicon.
Page 30

Tools And Test Equipment Required To Determine The

Value Of A Burnt Resistor
To successfully determine the value of a burnt resistor, you will need an assortment of tools, and
simple test equipment. Once you have the tools and test equipment, you will be ready to check all
burnt resistor problems that come your way. Gathering the proper tools from the beginning can save
time and frustration.
a) Digital Multimeter (DMM) – A good quality and accurate digital multimeter

determines the value of a burnt resistor more precisely
than an analog multimeter. DMMs are easier to read than
analogs. The liquid crystal display produces a direct
readout in numbers, so you don’t have to interpret a meter
scale. Some DMMs even have auto-ranging; they
automatically select the correct resistance range
depending on the resistor being read. If you don’t have
one, you may want to consider purchasing a new DMM.
The cost of DMM has come down to the point where they
are very competitive with analog meters.
b) Test Leads – Your DMM should have a good quality test lead. A good quality
and sharp test lead will make a good contact with the resistor you are
measuring. Besides, you will get a stable reading instead of a fluctuating
reading, which is very frustrating especially when you are checking a burnt
resistor. If you already have a DMM, make sure the tip is clean and sharp
because for some resistors, the gap of the stripe is very narrow and it can only
be reached with a sharp test lead.
c) Wise -Get a small wise to clamp on the resistors. Without a wise, checking the burnt resistor
value is quite difficult, as it will slip away when the meter test leads is placed on the
resistor.
Page 31

d) Wire Cutter – A wire cutter is useful to remove the protective layer of the resistor.
With some resistors, their color code has lost its vibrancy due to heat.
To determine the resistor value, we need to peel off the layer so that it
can be check by a DMM. Gently remove the layer without destroying
the thin coating of the resistive material. The resistive material is the
only clue to determine the burnt resistor value.
Note: The ceramic or silicon coated body of wire-wound resistor

also can be broken to gain access into the resistive material of the
resistor.
e) Magnifying Lamp – A magnifying lamp provides not only light, but also makes the resistor
markings easier to be read. When you check a burnt resistor, it is often
necessary to check for cracks and the burnt spot (which will be discussed
later). A magnifying lamp is perfect for this job.
Page 32

Step By Step Guide

There are four steps that you must follow in order to successfully determine the value of a burnt
resistor in a faster and easier way.
Step one: Identify the burnt resistor

Most often when resistors fail, they either increase in value or open up all together.
But in certain case, you can normally pick out an overheated carbon or metal-film
resistor visually. The resistor will have a darkened or even burnt appearance, and the
color bands will have lost their vibrancies. There may even be evidence of cracking or
blistering. Once you have identified the burnt resistor, solder it out and measure the
resistance. Not all burnt resistor will open up, with some burnt resistor the original
value still remain intact. After you have confirmed that the burnt resistor value have
opened up or gone up in resistance (many mega ohms), then only you start removing
the protective layer of the resistor. Do it gently, for you may accidentally break the
resistor into pieces. If this happens, it will be very difficult or impossible to determine
the value of the burnt resistor.
In nearly all cases of overheating, the resistor itself is not at fault; rather, some other
components, such as transistor, diode or capacitor, has either shorted out or has
become leaky. This causes too much current to flow through the resistor, which then
overheats. Generally, you will want to locate the cause of overheating first, and then
replace the resistor.
Step two: Total stripe count of a burnt resistor

It is important to find out how many stripes the burnt resistors have after you had
removed the protective layer. A half or one stripe may indicate the burnt resistor is
under 10Ω, two stripes may indicate the burnt resistor is under 100Ω, three stripes
may indicate the burnt resistor is under 1kΩ and so on. However, different type of
resistors may produce different results. With some hands-on practice on a certain type
of resistors, you will quickly identify to which range a burnt resistor belong (under
10Ω, 100Ω, 1KΩ and etc).
Note: Even though a resistor is burnt, you will still be able to see or count the
stripes of the resistor.
Step three: Using the right method

Not all resistors are burnt at the same area; some at the side, some at the center. In
some cases it might burn up 3/4 of the resistive material of a resistor. Even though it
is badly burnt there is still a method used to successfully identify the value. In the
coming topic, I will show you how to use the right method to tackle different kind of
burnt resistor problems.
Page 33

Step four: Retest

Once you have found the right value of the burnt resistor, retest the equipment
thoroughly to make sure that you have solved the problem. Do not be discouraged if
the equipment is still not working. Simply walk away, clear your mind, and start again
by defining the symptoms. Never continue with a repair if you are tired or frustrated –
tomorrow is another day. You should also realize that there might be more than one
bad component to deal with. Normally when one parts fails, it may cause one or more
interconnected parts to fail as well. Be prepared to make several repair attempts
before the equipment is repaired completely.
Note: Always use a replacement resistor with a power rating that is

equal to or greater than the original.
Page 34

The Right Method To Check The Value Of A Resistor With

Protective Layer Removed
As mentioned earlier, the more stripes a resistor has the higher resistance it will be, and the
fewer stripes a resistor has the lower resistance it will have. Thus, just by basing on the number
of stripes of a resistor you will be able to estimate the ohms range of the burnt resistor, whether it is
under 1Ω, 10Ω, 100Ω, 1kΩ, 10kΩ, 100kΩ, 1MΩ or even 10MΩ. Once the protective layer of a
resistor has been removed, you are able to see the total number of stripes (spiral grooves) on the
surface of the resistive material (carbon film or metal type).
The method on how to check the value of a resistor with protective layer removed is the same
regardless whether it is a one-stripe or eight-stripe resistor.
Let’s begin.
Note that every resistor has a spiral groove that is cut using a lathe or laser beam. There is a starting
and ending point as shown in Fig 19. Usually the starting point is near to the metal cap of resistor.
Fig 19: Showing a starting and ending point of spiral groove in a resistor
Page 35

Regardless of how many stripes a resistor has the measurement should be measured between the
right lead and ending point or left lead and starting point of a resistor as shown in Fig 20. Either
way will identify the exact value of the resistor.
a) Measuring between right lead and ending b) Measuring between left lead and
starting point point
Fig 20: The right method to check the value of a resistor with protective layer removed
Note: Do not let your test probe touch the spiral groove because it will show you an infinite
reading. With your test probe, touch only the adjacent of the spiral groove.
Page 36

The result that you achieved by measuring both points is not always exact, but at least you will
know the range to which the resistance belongs. For example, measuring between the ending point
and right lead of a resistor showed 11.3 to 12.5Ω (the resistance varies due to the movement of the
test lead or putting the probe at different distance near to the ending point) then the only resistor
that falls under this range is 12Ω. 12Ω is the original value of the resistor.
Although you now know how to determine the value of resistor with protective layer removed,
there is certain way of measuring the resistor that you should not use. For example:
a) Please do not measure a resistor after the ending point area as shown in Fig 21 because it will
produce a higher than normal resistance value reading.
Fig 21: Measuring this point (darkened area) should be avoided
b) Resistance should not be taken between the left lead can ending point as shown in Fig 22 as
this will produced lower than normal resistance value reading.
Fig 22: Avoiding measuring resistance between left lead and ending point
Page 37

c) Measuring between these points (darkened area) as shown in Fig 23 will also produce
inaccurate reading.
Fig 23: Showing the wrong way to check a resistor
Experimenting with a few resistors using a digital multimeter as you go back through the
material is an excellent way to gain greater understanding of how to check the value of
resistors with its protective layer removed.
You can purchase several types of resistors for less than $0.30 each from many electronic
suppliers. Get a few films, metal or wire wound types of resistor, break the protective layer,
grab your digital multimeter, and see for yourself. With some hands-on activity, it won’t take
you long to become confident in performing a resistor test (with protective layer removed)
and successfully be able to identify the value of a burnt resistor.
Page 38

Typical Examples Of Burnt Area In A Resistor And How To

Determine The Value
A burnt resistor does not always cause the ohms value to increase or become open. In some cases,
the ohms value still remain the same even though the resistor already burnt into crisp or the color
bands have lost its vibrancy due to overheat. In other cases, the value might increase a little bit than
the original value and a near replacement value might put the equipment back to work again. For
example, a burnt resistor measured 113Ω, and the nearest replacement value would be 100Ω. Note
that a spoilt resistor can either become open circuit or increase in resistance. Since there is no 110Ω
resistor in the market, the only nearest value available is 100Ω.
Always check a burnt resistor value first before starting to ‘peel off’ the protective layer, because a
burnt resistor can be very fragile especially when applying force on it with wire cutter. Who knows,
the measurement you get from the burnt resistor is the resistor original value. If you accidentally
break the burnt resistor into pieces then you might not be able to find the value of the resistor.
Problem 1: Color band fade out or missing due to the use of cleaning solvent
Solution 1: Color band fade out or missing due to the use of cleaning solvent such as thinner will
not cause the value of the resistance to vary. Usually the measurement you get is the
resistor’s original value. You can always check if the resistor is in good condition by
removing the protective layer of the resistor. If you can see a smooth resistive
material on the surface without any defect then most probably the resistor is good.
Another way to confirm is to examine the value you get from the measurement. Say,
if you measured the resistor and showed 46.5 or 46.8Ω then you knows that it is a
47Ω resistor. But, if the reading showed 41.3Ω then most probably there is a problem
with the resistor because the value you measured (41.3Ω) is out of the typical resistor
value list. Although the value (41.3Ω) might be found in certain precision design of
circuit but it is extremely rare. If you suspected that the value you measured is not the
resistor original value then you may use the method described at previous topic to
confirm it.
Problem 2: Color band fade out or missing due to overheat with protective layer still intact
Solution 2: In this case, the resistor will usually have a darkened or even burnt appearance, and
the color bands will have lost their vibrancy. There may even be evidence of cracking
or blistering. There is a 50 percent chance that the value you measured is the resistor
original value. As mentioned earlier, an overheat resistor does not necessarily always
cause the ohms value to vary or become open. Follow the explanation on solution 1 to
find the original value of the suspected resistor.
Page 39

Problem 3: Resistor leads became rusted due to water entering into PCB board or electrolyte
from electrolytic capacitor
Solution 3: If the resistor leads have become rusted even though the color band is not affected, it
is always recommended to replace the resistor with a new one. A rusted resistor leads
can cause intermittent problem, noise, resistance value run and etc. Do not take the
risk of not replacing the rusted resistor. A new resistor cost less than 30 cents as
compared to the time you wasted checking an intermittent problem caused by only a
rusted resistor leads. To find out the value, simply calculate the resistor value based
on the color band of the rusted resistor.
Problem 4: Burnt areas at the side of a resistor as shown in Fig 24
Fig 24: Burnt area of a resistor
Solution 4: In this case, you have to put your probe at right lead and the other probe to the ending
point of the resistor as shown in Fig 25.
Fig 25: Checking the resistor original value between right lead and ending point
The resistance read-out is the value of the resistor original value. Do not measure the
resistor between left lead and ending point, as this will only showed high resistance or
infinity reading.
Note: If the burnt area at the right side of a resistor as shown in Fig 26, then you must
measure it between left lead and the starting point as shown in Fig 27.
Page 40

Fig 26: Burnt area of a resistor
Fig 27: Checking the resistor original value between left lead and starting point
Page 41

Problem 5: Nearly half of the resistor is burnt as shown in Fig 28
Fig 28: A resistor burnt nearly half of the part
Solution 5: First determine how many stripes the burnt resistor has. Assuming it has 3 stripes then
most probably the resistor’s value is under the range of 100Ω. To find out the value of
the burnt resistor, simply connect the meter’s probe to the right lead and center of the
resistor as shown in Fig 29.
Fig 29: Measurement taken between center of resistor and right lead
Say if the measurement showed somewhere between 45 to 52Ω then use these value
to multiply by 2 (because you are measuring half of the resistor), which gives the
range of 90 to 104Ω. There are two values that you can choose from i.e. 91Ω or 100Ω.
To know which the correct value to replace is, simply look at the first stripe of the
color band of the resistor. If it is white color band then choose 91Ω, and if it is brown
color band then you choose 100Ω. If you only can see a gold color band, then you
have to try out either 91Ω or 100Ω to see which one makes your equipment perform
normally.
Page 42

Problem 6: Burnt at the center of resistor as shown in Fig 30
Fig 30: Burnt area at the center of resistor
Solution 6: As usual, see how many stripes this resistor has. In the above case it has only two
stripes, which indicate the value is under the range of 10Ω. Measurement should be
made between right lead to the side of the spiral groove as shown in Fig 31.
Fig 31: Measurement taken at the side of spiral groove and right lead
If the measurement showed 4.7 to 5.1Ω then use these value to multiply by 2 (because
it has only two stripes) resulting in a range between 9.4Ω and 10.2Ω. Since this
resistor has only 2 stripes, the best value to choose is 10Ω.
Say if the burnt resistor has 3 stripes and the measurement you get is between 29Ω to
34Ω then using this value to multiply by 3, which gives 87Ω to 102Ω. Since this
resistor has 3 stripes, the best value would be 100Ω. Again it depends on the first
color band of the resistor as explained in solution 5.
Page 43

Using Comparison Method

If you want to make sure that the burnt resistor value you have determined is the right value before
you replace and switch on the equipment, you can always use the comparison method to find out.
For example, if you have determined a burnt resistor value, which is 47Ω and you are unsure if this
is the correct value, in order to find out you have to use a similar type of resistor (film or wire-
wound) with same wattage rating (1/2W, 1W, 2W or 5W). Get a new 47Ω resistor and remove the
protective layer with wire cutter. Now compare the reading as shown below.
a) Measuring a burnt resistor value b) Measuring a good 47Ω resistor
Fig 32: Using comparison method to check if the burnt resistor value is actually 47Ω
Since both resistors are from the same type and wattage rating, it should produce a close result
when doing comparison. In Fig 32a, measuring point A gives the result of 23Ω while measuring
point B shows 47Ω. If using the similar method in checking the resistor in Fig 32a check on a new
resistor (Fig 32b) and if it shows almost the same result say 46.5Ω then most probably the burnt
resistor is 47Ω. If point A in Fig 32b shows 23Ω and point B shows 68Ω then most probably the
burnt resistor value is also 68Ω and not 47Ω.
Comparison method is used if you are uncertain of the value you have determined from a burnt
resistor.
Page 44

True Case Histories

Five actual burnt resistors case histories
The following are five actual problems and their solutions.
Case No 1:
This monitor came in with no power symptoms. But upon checking, found a ¼ watt resistor badly
burnt at its power side. When the resistor measured showed infinite reading. By looking at the color
band i.e. the blue and gold color, it could indicate the resistor to be somewhere in the range of
0.62Ω, 0.68Ω, 6.2Ω, 6.8Ω, 62Ω, 68Ω, 620Ω, 680Ω, 6.2k, 6.8k, 62k, 68k, 620k, 680k, 6.2MΩ or
even 6.8MΩ. This is a very wide range. In order to narrow down the search, simply remove the
protective layer and clean the resistor with a brush. Once the protective layer had been removed,
only two stripes can be seen, which mean the resistor is under the range of 10Ω, eliminating the
guessing game of other possible values.
By measuring between the metal film layer and the right lead as shown in Fig 33, it produced 1.7Ω.
Fig 33: Measuring between the metal film layer and right lead after the protective layer had
been removed
This value indicated that the resistor was more than 1.7Ω but less than 10Ω. Since the first color
band was blue, then most probably the value was either 6.2Ω or 6.8Ω. I chose 6.8Ω because it was
more widely used. After substituting the resistor, the monitor worked perfectly.
Note: Besides the resistor that was problematic, the power FET and SMPS IC also shorted.
Page 45

Case No 2:
This 1/4w resistor was badly burnt and only the orange color band could be seen. Measuring the
resistance showed 116Ω. With the measurement reading (116Ω), we knew that the original value
was lower than 116Ω. So the value could be 0.33Ω, 0.39Ω, 3.3Ω, 3.9Ω, 33Ω or 39Ω.
To find the right value, we removed the protective layer. Once the protective layer had been
removed, the three stripes meant that it was in the range of more than 10Ω and less than 100Ω. The
only values falling on this range was either a 33Ω or 39Ω resistor. I tried the 39Ω resistor first and it
cured the problem.
Case No 3:
Fig 34: Checking the value of a burnt resistor
The monitor came in with no high voltage and I found a resistor with the color band, having lost its
vibrancy due to overheat. Measuring the resistor produced very high ohm reading in mega ohms.
Gently removing the protective layer I found a slight burnt at the side of the resistor. Measuring the
resistor between the ending point and the right lead as shown in Fig 34 produced a 1.285kΩ
reading. Replacing a new 1.2kΩ resistor solved the no high voltage problem.
Note: The overheating caused the resistance value to increase a little bit higher than the
original value.
Page 46

Case No 4:
Fig 35: Usually 4 stripes resistor is in the kilo ohms range
Acer monitor model 7254e had no display. Upon checking the flyback, I found that the internal
diode had shorted. Usually when the internal diode is shorted in the flyback, it will cause
components along the Automatic Blanking Limiter (ABL) line to be burnt. The burnt resistor
caused the controlling contrast not to function in the monitor. Tracking the ABL line I found the
R355 1/4W resistor burnt. All the color couldn’t be seen. The burnt resistor measured 11.01kΩ.
Removing the remaining protective layer, it showed it had 4 stripes, which meant it belonged to the
kilo ohms range. Measuring between the right lead and ending point, it showed 9.95kΩ as shown in
Fig 35. Replacing the burnt resistor with a 10kΩ resistor cured the fault.
Case No 5:
Fig 36: More than 6stripes resistors usually values more than the 10 kilo ohms range
No power was the complaint of this 17” supreme monitor model: BM17GLC. Upon checking the
power section I found a 2-watt resistor, with its color band having lost its vibrancy except for the
first blue color band. Measuring that resistor with a meter showed an open reading. Peeling off the
protective layer of the resistor I found that it had a burnt mark near to the ending point. This resistor
had 6 stripes, which meant it was above the 10 kilo ohms range.
Placing the probe near to the burnt mark and right lead as shown in Fig 36 it measured 62 kilo
ohms. Since this resistor first color band started with blue, then most probably it was in the range of
62kΩ or 68kΩ. I believed the burnt mark had eaten up the remaining 6kΩ value. Replacing the
resistor with a 68kΩ 2W value solved the no power problem.
Page 47

Conclusion
Wow! Now you’ve possessed a complete roadmap to determine the value of a burnt resistor.
Do not expect to be an expert in a few minutes as it takes patience and time. It is normal to have
some trouble at the beginning. Try experimenting with a few resistors using a digital multimeter as
you go back through the materials. Take your time, as I promised you, it will be worth spent! You
will be able to determine the next burnt resistor value in no time …
Drop me a line and let me know how you’ve progressed!
Thanks again – Happy finding burnt resistor values!
To your success,
Jestine Yong
http://www.ElectronicRepairGuide.com
http://www.TestingElectronicComponents.com
http://www.JestineYong.com
Page 48

About The Author
Jestine Yong
Jestine Yong graduated as an Electrical And Electronic

Engineer in Robert Gordon University Aberdeen UK. He
has been repairing computers since 1991. During his
tenure as an engineer, he has worked on a wide range of
electronics repair. When not repairing computers, he’s
busy designing new methods to solve electronic repair
problems. He owns and operates a successful computer
repair business since 1996. His plan is to go into full-time
writing.
Jestine lives in Kuala Lumpur, Malaysia with his wife, Michelle Tan, and is blessed with two lovely
children – Noah and Hannah. He enjoys writing, internet marketing, reading, traveling and fishing!
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How To Find Burnt Resistor Value Even Without A Schematic Diagram

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4. POWER RATING OF RESISTOR…………………………...……………… 11

5. VOLTAGE RATING OF RESISTOR………………......……………………. 11

6. RESISTOR COLOR CODE………………………………....……………….. 12

7. TYPICAL EXAMPLES ON HOW TO CALCULATE RESISTOR COLOR

8. CODES INDICATING VALUES AND TOLERANCES..………………….. 18

9. SURFACE MOUNT RESISTOR CODING…………………………………. 19

10. RESISTORS IN SERIES AND IN PARALLEL……………………………... 20

11. WHY CONNECTING RESISTOR IN SERIES OR PARALLEL IS

12. APPLICATIONS OF RESISTORS IN ELECTRONIC CIRCUITS…………. 23

13. HOW RESISTOR FAILS?………………………………………….………... 24

14. TESTING OF RESISTORS…………………………………………………... 25

15. RESISTOR REPLACEMENT………………………………………………... 27

16. TYPICAL RESISTORS VALUE…………………………………………….. 28

17. LET’S GET STARTED – CONSTRUCTION OF A FILM TYPE

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18. TOOLS AND TEST EQUIPMENT REQUIRED TO DETERMINE THE

19. STEP-BY-STEP GUIDE……………………………………………………... 33

20. THE RIGHT METHOD TO CHECK THE VALUE OF A RESISTOR

21. TYPICAL EXAMPLES OF BURNT AREA IN A RESISTOR AND HOW

22. USING COMPARISON METHOD……………………………….…………. 44

23. TRUE CASE HISTORIES…………………………………………………… 45

ABOUT THE AUTHOR…..…………………………………………………. 49

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Very special thanks to Timothy Wong who edited the manuscript.

Limit of Liability / Disclaimer of Warranty:

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Fixed Resistors Variable Resistors Tapped Resistors

Fig 1: Symbols for resistors

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a) Carbon Composition Resistors

Carbon composition resistors are rarely used in modern Fig 2: Carbon

b) Film Type Resistors

i. Carbon Film Resistors

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The disadvantages of carbon film resistors are:

a) Ceramic Body b) Silicon Coated

c) Vitreous Enamel d) Aluminum Housed

Fig 5: Types of wire-wound resistors

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a) Single Inline Package (SIP) b) Dual Inline Package (DIP)

Fig 7: Resistor Networks

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a) Single Turn Potentiometer b) Slider Potentiometer

Fig 8: Typical Potentiometers

Fig 9: Trimmers or Presets

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Fig 10: Wire-wound Rheostat

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Power Rating of Resistors

Voltage Rating of Resistors

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Resistor Color Code

Colour Digit Multiplier Tolerance

Fourth Band Blue 6 1000000 -

Gold - 0.1 +5%

Silver - 0.01 +10%