Industrial Training

Industrial Training Blog

Advanced Electrical Troubleshooting

How to troubleshoot industrial controls with advanced Troubleshooting Industrial Controls skill training simulation software. Advanced training to troubleshoot problems with skills test. Read more at Advanced Electrical Troubleshooting simulations.

advanced-troubleshooting-skill-training-test

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August 13, 2017 Posted by | Education, Electrical, engineering, maintenance, PLC, safety | , , , , , , , , , | Leave a comment

How to troubleshoot with a PLC

How to troubleshoot with a PLC is the most common practice.

PLC Technician

Troubleshooting PLC itself is a much less common practice. As PLCs are so reliable. PLC (Programmable Logic Controllers) where designed specifically to be more reliable thank a computer, and more simple so a maintenance technician could work with them, including use them to troubleshoot the machine and automation control process.

The PAC (Process Automation Controller) on the other hand is much more complicated as it is a customized industrial computer, designed with computer IT and programmers in mind, not the maintenance technician or electrician. Likewise, the PAC is a lot less useful for troubleshooting machines and automation control systems. Actually, in that respect, the PAC is the opposite due to its complicity. It is more common end-users (process and manufacturing maintenance personnel)  will be troubleshooting the PAC itself more than using it as troubleshooting tool for the machine. Read on to learn why…

Given that PLC vendor’s intent was to make the PLC easy for the maintenance electrician to use, beyond just using ladder logic as programming language, the added many great software tools to aid the maintenance electrician in troubleshooting machines. You wont find most of these PLC troubleshooting software tools and design features in a PAC. Below are just a few examples. At the end of this article will be a link to read about more. To learn about all of the PLC troubleshooting tools and techniques, and to master PLC troubleshooting, there is currently only one way, attend a hands-on PLC Troubleshooting Training Seminar in St. Louis.

How to troubleshoot with a PLC | Basics

In the real world, 99% of the time, the problem with a machine or process is not the PLC, it is an Input or Output. In other words, it is one of the hundreds of sensors, switches, solenoids, etc. gone bad, out of adjustment or not be made. If the people who wrote the PLC program used PLC programming best practices, the PLC program will be well documented ladder logic. (A symbolic programming language as easy to troubleshoot as looking at a ladder and seeing what rung is broke on the ladder. )

Given the above, based on symptoms reported, you search PLC program for the input or output not working, then trace back through the ladder logic to find out what contact is not being made and that is the sensor or switch causing the problem that you need to look at out in the real world. most of the time that is how you troubleshoot with a PLC, simple as that and takes about 4 minutes to find root cause. (If you have been properly trained by BIN95.)

But … in real life it is not always simple, just most of the time with a PLC. There can be intermittent problems, analog problems, poor management of automation equipment in your facility, etc.

FYI:  Management of PLCs in your facility is also taught in BIN95 PLC Training seminars.

Those little more complex PLC troubleshooting instances that occasionally come up is where PLC troubleshooting software tools that vendors provide, come in. Read How to troubleshoot PLC Allen Bradley to learn more. Below are a few excerpts…

For more cumbersome troubleshooting like intermittent problems, RSLogix 500 has great tools like the Histogram, Custom Data Monitors, trend charts, writing your own diagnostics rungs using Latch bit, etc.

Rslogix 500 Custom Data Monitor    RSLogix 5000 Trend Charts

One example of real world troubleshooting we teach, which is not in books or software, is using RSLogix 500 program “Compare Tool” (Compare Tool may be in your version of RSLogix 5000, or as a separate software for PACs. Or you might not have the tool if you are using PACs, instead of PLCs to control your machinery.) Those not spending years maintaining a PLC/PAC controlled facility may not be aware of the common scenario of one employee on one shift changing the program, and the rest don’t know it. If the troubleshooter suspects that, they can use the program compare and once again within about 15 minutes, find the problem.

PLC Troubleshooting tool

System Data Tables and other data tables found in a PLC (like RSLogix 500) are great troubleshooting tools too, but are not in PACs (like RSLogix 5000). This is another major factor contributing to the use of PACs resulting in increased troubleshooting and downtime. In BIN95’s instructor based PLC training, we also teach best practices in writing PLC programs, so attendees can identify if they are being used before purchasing new machines or systems controlled by PLCs. (Like RSLogix 5000 programmer compensating for missing data table files in their tag naming conventions, for example.) Having a program that was written using PLC programming best practices, with the end user in mind (customer who has to maintain equipment for the next 10-20 years), greatly reduces troubleshooting time. … continued at https://bin95.com/rslogix-5000-troubleshooting.htm

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July 24, 2017 Posted by | Education, Electrical, maintenance, manufacturing, PLC, PLCProfessor, Skill Shortage | Leave a comment

Rockwell RSLogix 5000 Training Seminar

Instructor: The PLCProfessor

Date: 9/26/2017 – 9/28/2017

Location: St. Louis, MO USA

Rockwell RSLogix 5000 Training Seminar starring The PLC Professor!

If you liked the PLCProfessor books and the PLCearn series, now is your chance to get hands on Controllogix – Compactlogix and RSLogix 5000 PAC training in person with the PLCProfessor!

PLCProffesor-RSLogix-5000

3 – Day RSLogix 5000 PAC Training Workshop

This 3 days of PAC training labs on real Compactlogix PACs is phase 1 of PAC training; Programming Ladder Logic with Rockwell’s  Studio 5000. (2.4 CEUs )

BIN95 offer The Best for Less once again with all the extra free PAC/PLC training material (see below)  each attendee takes home with them. The effective cost for all three days, once you deduct the value of free PLC training material, is about $1000 for all 3 days! That’s only $330 per day while everyone else charges over $500 per day. Plus it is not just anyone giving you that valuable hands on training, BIN95 and The PLC Professor specialize in automation training.

Undeniably, The Best for Less!
Register today, tap RSLogix 5000 Training Seminar for more details and to register.

July 9, 2017 Posted by | Education, Electrical, engineering, maintenance, PLC, PLCProfessor | , , , , , , , | Leave a comment

Bug free PLC programming example – 21 CFR Part 11

Source: PLC programming examples under GMP GAMP 5

PLC programming example

GMP (Good Manufacturing Practice), GAMP 5 (Guide for Validation of Automated Systems), 21 CFR Part 11. IEC 25010

Best practices in the PLC programming realm, uses Static Analysis (verification testing). It is probably one of the least covered in PLC training, and therefore least practiced. (With those receiving BIN95 PLC training being an exception to that rule as they have always covered it in the instructor based classes since 1995.) Yet it should be one of the most important parts of the automation control design phases.

See 5 reasons why static analysis of PLC programming is very important.

The most important being Safety, Maintainability and Cost Savings over the life cycle of the equipment that PLC code controls. Many machine designers and system integrator claim they do not have the budget to do static analysis to GAMP 5 level of quality. The cost of not doing so, is passed on to you (the end-user of the equipment) for the life of the equipment.

That cost to end-user, when measured in using TDC (True Downtime Cost), can and often is … astronomical over the life of the equipment.

March 23, 2017 Posted by | Education, Electrical, engineering, maintenance, manufacturing | , , , , , , , , | Leave a comment

OPC for SCADA and DCS training

What does OPC stand for? OPC = OLE for Process Control

What does OLE stand for? OLE=Object Linking and Embedding

opc-training

OPC communication protocol is the most current to standardize data transfer between all industrial devices. Which make OPC training essential to those working with IIoT.

(IIoT=Industrial Internet of Things)

For OPC SCADA and DCS, this OPC training and software gives you real world experience on free OPC server.

Source: OPC for SCADA and DCS training

February 7, 2017 Posted by | Education, engineering, manufacturing, PLC | , , , , , | Leave a comment

Siemens PLC Programming Example 1

This PLC programming example PDF expands on last post where we started looking at the Siemens PLC counter using the Siemens PLC simulator.plc-programming-example-pdf

To open PDF, click “Siemens PLC Programming Example PDF

Source: Siemens PLC Programming Example 1

December 23, 2016 Posted by | Education, Electrical, engineering, maintenance, PLC | , , , , , | Leave a comment

Online MCC Electrical Training

This online motor control center training certificate course for beginners.

Source: Online MCC Electrical Training It is also great for a refresher. Below is a little video tour and demo of the MCC electrical Course…

December 16, 2016 Posted by | Education, Electrical, engineering, maintenance, manufacturing, safety | , , , , , , , , , | Leave a comment

Mechanical Engineering Career Aptitude Test

ME aptitude tests (MAT) are one of the most common, they measure knowledge of mechanical engineering technology, electrical, and physical concepts.

Source: Mechanical Engineering Career Aptitude Test

The article above covers how to study for the mechanical aptitude test (MAT) that are commonly used today. There is mechanical aptitude test preparation for Bennett (BMCT test), the Wiesen test (WTMA test), the Ramsay Corporation test and the Military’s ASVAB test preparation.

As well as the Military using the ASVAB for pre-screening, big corporations like Delta airlines, AT&T, Dupont, and Amtrak.

Bennett test (BMCT test) – Used for industrial and repair positions jobs.

Wiesen test (WTMA test) – Used in the operating, maintaining and repairing machinery industries, and deals more with day to day operations.

Ramsay test – Used to identify and sort potential candidates for trainee programs and apprenticeships.

ASVAB test – Used by the military as mechanical aptitude test.  Includes questions about general science, electronics information, auto information, shop information and mechanical comprehension.

November 28, 2016 Posted by | Education, engineering, maintenance, Mechanical, Skill Shortage | , , , , , , , , , | Leave a comment

RSLogix 5000 Programming

A ControlLogix – RSLogix 5000 Tutorial

Check out the RSLogix 5000 Tutorial to get started with understanding the structure (architecture) PAC RSLogix 5000 programming.

studio-5000-tutorial

A ControlLogix project is comprised of tasks that contain programs routines and other elements. Tasks within the project set the execution priority for one or more programs and schedule the program’s execution with up to 32 tasks available.

The programming task are configured to execute

Continuous: The continuous task is executed continuously as long as periodic or event tasks are not being executed. When the continuous task completes a full scan, it restarts immediately.
Periodic: Periodic tasks perform a function at a specified interval. Configurable time periods range from point 1 milliseconds to 2,000 seconds. Priorities assigned, range from 1 to 15.
or Event-based:Event task are executed immediately when a specific trigger occurs. A trigger is defined by the user and can be a change of state of an input or specific motion control operations.

In summary tasks are executed one at a time depending on their priority and only one task is continuous.Learn more see RSLogix 5000 Tutorial

October 18, 2016 Posted by | Education, Electrical, engineering, maintenance, PLC | Leave a comment

Electrical Engineering: Why is there so much theoretical in BSEE programs?

bsee-electrical-engineering-students

This article answers –

Why so much theoretical in BSEE college Electrical Engineering programs and not much practical application?

It answers in a unique way that may be more understandable by students asking that question. See and share …

Source: Electrical Engineering students: Why so much theoretical?

October 3, 2016 Posted by | Education, Electrical, engineering | , , | Leave a comment

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