Industrial Training

Industrial Training Blog

New Free Online Electrical Troubleshooting Simulator

The new free online Industrial Electrical Troubleshooting Simulator Game (V4) is out!

Industrial Electrical Simulator Game

Even a simple electrical circuit like this conveyor motor control circuit, can have many faults. The free online electrical simulation game is designed so you can have a little fun while practicing your troubleshooting skills.

Designed for Chrome and Edge browsers (works with Firefox too). So you can play the game on your phone’s browser, tablets, PC, Mac, even 4kTV! Of course a bigger screen than a phone is best, like tablets and computer screens.

Real-time volt meter readings, interactive electrical diagram, official LOTO steps, shows True Downtime Cost ‚ĄĘ and has FUN electrical fault scenarios!
  • Game Level 1: How to use walk through.
    • Lockout/Tagout training (LOTO)
    • Upon completion unlocks Skill Test Level
    • Max score 100
  • Game Level 2: Skill Test mode
    • Five Electrical Faults to solve
    • Also intermittent fault when the conveyor vibrates
    • Fail to do LOTO, player electrocuted, has to start game from beginning.
    • Max score 100
    • Upon completion unlocks Rando mode
  • Game Level 3: Rando mode
    • 5 Random electrical faults to solve.
    • It’s a race against the clock.
    • Max score 600
    • Upon completion unlocks all modes so user can any level, anytime!
    • Upon completion unlocks new interactive electrical diagram showing live voltages and currents
Please subscribe to our YouTube channel too for more educational videos.

Please rate and share with your friends and associates. (They need to have fun too!) Seeing the industrial electrical troubleshooting game shared a lot will encourage us to add new features and functionality. So please share , share. ūüôā Thanks

Rating: 5 out of 5.

August 8, 2020 Posted by | Uncategorized | | Leave a comment

Electrical Troubleshooting Simulator

Free Online Electrical Troubleshooting simulator:


Free Online Electrical Troubleshooting Simulator

This online electrical troubleshooting training simulator game app, is like no other. It is compatible with Smartphone’s, tablets, PC, Mac, even 4kTV! Designed for Chrome and IE browsers (works with other browsers too, but currently not compatible with firefox). Unlike others, this training app includes the official 6 step lockout tagout safety procedure training, also includes environmental and intermittent simulated electrical faults and allows you to use all 5 senses to troubleshoot!

O.E.T.S: [pronounced ‘oats’] – The only free Online Electrical Troubleshooting Simulator in the world.

Have you had your OETS today?

Continue reading

February 17, 2019 Posted by | Education, Electrical, engineering, maintenance, safety | , , , , | Leave a comment

Emergency power plan – electric diesel generator maintenance

Emergency Power Plan – Generator Maintenance. << Click to download !!

Electric Diesel Generator

How to researched, set up and operated a new electric diesel emergency generator maintenance team. Learn from Larry Bush as he leads his maintenance team thru the research to Purchase, Setup and Maintain Emergency Diesel Electric Generators for an international oil company.

Chapter 1


Chapter 2


Chapter 3


Chapter 4


Chapter 5


Chapter 6

  • IN SUMMARY (96)

Free Book samples: (See )

May 30, 2015 Posted by | Education, Electrical, engineering, maintenance | , , , , , , , , | Leave a comment

Engineering Funny Connections – YouTube

Just added #Funny #HVAC to our Engineering Funny Connections РYouTube.

Though you all might like and share. You can learn and laugh at the same time!

June 26, 2013 Posted by | Education, Electrical, engineering, Humor, Lean, maintenance, manufacturing | , , , , , , , , | Leave a comment

PLC Training Assessment from Employee Training Assessments

PLC Training Assessment from Employee Training Assessments.

Attention: Maintenance, Electricians, Engineering …

Test your self, test your employees, share with others and compare scores, have fun! Click the link above !

(no registration, email or any contact info required. totally free)

March 14, 2013 Posted by | Education, Electrical, engineering, maintenance, manufacturing, PLC, Skill Shortage | , , , , , , , , | Leave a comment

Best Practices for PLC Programming

Best practices PLC programming

PLC Programming

September 27, 2012 Posted by | Uncategorized | , , , , , | Leave a comment

Free Online PLC Training Interactives

Allen Bradley Data File training

Click to Learn

A set of 4 free online interactive memory tools to learn and memorize the Allen Bradley Data Tables. Totally free, no registration or email required. Just use and share with others. The decision to make more training tools on other topics will depend on how popular these are.  So if you like the tools, be sure to share with as many others as you can. also there is a comment area where you can recommend other topics you would like to see.

(And thanks to our January PLC training graduates who requested we make a memory tool for PLC Data Types.)

January 21, 2012 Posted by | Electrical, engineering, manufacturing, PLC | , , , , , , , , , , , | 6 Comments

BIN Brings ControlLogix ‚Äď RSLogix 5000 Training Seminar Home

See press release¬†BIN Brings ControlLogix ‚Äď RSLogix 5000 Training Seminar Home.

May 5, 2011 Posted by | Electrical, engineering, manufacturing, PLC | , , , , , , , , , , , | 1 Comment

How to do Electrical Troubleshooting of Electrical Motor Control Circuit

This video uses Electrical Troubleshooting Simulation software to teach you how to troubleshoot an electrical motor control circuit. At the end is just an example how our software uses realworld workorder system to track student while doing electrical troubleshooting with our simulation software, and the detailed analysis report. (helps student learn better ways to troubleshoot.)

February 21, 2010 Posted by | Electrical, engineering, manufacturing | , , , , , , , , , | Leave a comment

Maintenance Management of your company’s PLC

(Programmable Logic Controller).

By Don Fitchett

(This article also featured in November 15, 2007 Chemical Engineering Magazine)

  • What is a PLC?
  • How many PLCs is your bottom line depending on?
  • Do you have an up to date list of all PLC model types, part availability, program copies, and details for your company?
  • Do you have at least one trained person per shift, to maintain and troubleshoot your plant PLCs?
  • Does your maintenance personnel work with PLCs following written company or corporate policy, and procedures?

If you could not answer with confidence or you answered ‚ÄėNo‚Äô to any of the above questions, you need to read this article on maintenance management of PLCs. Why? Because the PLCs (Programmable Logic Controllers) are the brains of your operation. When the PLC is not functioning properly, lines shut down, plants shutdown, even city bridges and water stations could cease to operate. Thousands to millions could be lost by one little PLC in an electrical panel that you never even knew existed. But most importantly, damage to machine and personnel could result from improper maintenance management of your company‚Äôs PLCs.

What is a PLC?

First I‚Äôd like to explain in the most¬† non-technical terms possible, What a PLC is. As this article is not just for the maintenance technician, but for maintenance managers, plant managers and corporate managers. A PLC (Programmable Logic Controller) is the type of computer that controls most machines today. The PLC is used to control AND to troubleshoot the machine. The PLC is the brain of the machine. Without it, the machine is dead. The maintenance technicians we train, are the brain surgeons. That is how I explain it to my doctor any way. (His mouth drops open, ‚Äú… you train brain surgeons?‚ÄĚ)

Important Note: Just as a doctor asks the patient questions to figure out what is wrong, a maintenance technician asks the PLC questions to troubleshoot the machine. The maintenance technician uses a laptop computer to see what conditions have to be met  in order for the PLC to cause an action to occur (like turn a motor on). In a reliable maintenance management environment, the maintenance technician will be using the PLC as a troubleshooting tool to reduce downtime.

A little more detailed definition of a PLC: A programmable controller is a small industrial strength computer used to control real world actions, based on its program and real world sensors. The PLC replaces thousands of relays that were in older electrical panels, and allows the maintenance technician to change the way a machine works without having to do any wiring. The program is typically in ladder logic, which is similar to the wiring schematics maintenance electricians are already accustomed to working with. Inputs to a PLC can be switches, sensors, bar codes, machine operator data, etc. Outputs from the PLC can be motors, air solenoids, indicator lights, etc.

How many PLCs is your bottom line depending on?

My company has had an ongoing PLC related global maintenance survey since the year 2000. The majority of the participants back in 2001, reported 3-6 PLCs in their facility, that they know of. Granted most participants are managers and don’t open electrical panels much, but many of the participants are from fortune 500 companies having hundreds of employees. The odds are most of them have 12-30 PLCs in their facilities. Currently the average is 6-9 reported, so the good news is the industry as a whole is becoming more PLC aware.

It is common to only learn about a PLC once the machine is down and the clock is ticking at a thousand dollars an hour, or more. Unfortunately, it is also common that after the fire is out, it’s on to the next fire, without fully learning what can be done to avoid these costly downtimes in the future, and in other similar machines in a company or corporation.

Some older electrical panels may only have relays in them, but most machines are controlled by a PLC. A bottleneck machine in your facility may have a PLC. Most plant air compressors have a PLC. How much would it cost if the bottleneck or plant air shut down a line, a section of your facility, or even the entire plant?

Do you have an up to date list of all PLC model types, part availability, program copies and details for your company?

The first step to take is to perform a PLC audit. Open every electrical panel, and write down the PLC brand, model, and other pertinent information. Then go the next two steps. Analyze the audit information and risk, then act on that analysis. To help you out, I want to share with you our company PLC audit form.

Collected Information Recommended Action
Machine or Area Name Ex: warehouse conveyor, pump station 3,Strapper 2, Line 7, Traffic signal west main, etc.
PLC Program Name Ex: 1789GAA1, P3, Strap2, 5872443, WestMainTL, etc.
Network Node Address No two addresses will be the same. Ex: 2, 3, 17, 21
Network Name Common to be same as Program name, but not mandatory.
PLC Brand Ex: Allen Bradley, Siemens, Schneider, Mitsubishi, DirectSoft, Omron
PLC Model Number Ex: PLC-5/25, SLC-504, SIMATIC S5, MELSEC FX1N, DL 405
Is Spare Available Yes on shelf, or only in less critical machines or no
Date Program Last Backed Up Make program backups part of your semiannual PM program
Discriptored Copy of program available Without discriptored copy of program, troubleshooting and downtime are greatly increased.
Does PLC have EEPROM Or other method of storing backup program in a chip on PLC
Last date Program Changed Remember to log when outside consultants or OEM make  program changes too.
Last date EEPROM Burned Should be saved to EEPROM (Burned) after every successful program change.
Date battery last changed See manufacturer’s data for recommended change frequency.
Other information you may need Might be facility location when corporate HQ is using this form.

Once you have collected the basic information in your Plant wide and/or corporate audit, you need to analyze the information to develop an action plan based on risk analysis. In the risk analysis, bottlenecks and other factors will help you assess priorities. Starting with the highest priority PLC, you will need to ask more important questions.

o        Do we have the most common spares for the PLC?

o        Is the OEM (Original Equipment Manufacturer) available 24/7? Or even in business any more?

o        Do we have a back up copy of the PLC program?

o        Does our program copy have descriptions so we can work with it reliably and efficiently?

o        Do we have the software needed to view the PLC program? Are our maintenance personnel trained on that PLC brand?

These are some of the questions our managers must ask, to avoid unnecessary risk and to insure reliability.

Do you have at least one trained person per shift to maintain and troubleshoot your plant PLCs?

Is your maintenance staff trained on the PLC? (Silly to squander over a couple thousand in maintenance training when the lack of PLC knowledge could cost you 10 thousand an hour. … or worse. I can give you a couple good reasons why you should have at least one trained person per shift, to work reliably with PLCs. You do not want to see greater downtime on off shifts because the knowledge base is on day shift only. Also with all the baby boomers (our core knowledge base in the industry) about to retire, it is not smart management to place all your eggs in one basket.

Then the question should be asked, what should we look for in training. Well I have been training individuals for over a decade and could easily write another article on just PLC training alone. I can tell you here, that you should seek training with two primary objectives.

1.      The training you decide on, should stress working with PLCs in a Safe and Reliable way. (not just textbook knowledge or self learned knowledge)

2.      Secondly, the training should be actually centered around the PLC products you are using or plan to use in your facility.

I feel the two criteria above are the most important. Some other good ideas to get more out of your PLC training investment would be to get hands on training using the actual PLC programs and software the maintenance technician will be working with in the facility. Insure your personnel have the software, equipment and encouragement to continue with self education. PLC Training CBT (Computer Based Training) CDs are a great way for employees to follow up 6 months after the initial training. Some other ideas you could do is to provide them with simulation software and/or a spare PLC off the shelf to practice with.

Does your maintenance personnel work with PLCs following written company or corporate policy and procedures?

It seems that in our industrial culture, if policy and procedures are not written and enforced, we eventually stray back to the old unreliable ways. I have reviewed many policy and procedures as well as books on the topic matter and hardly ever see maintenance management of the PLCs included. It amazes me how an organization can write guidelines for what they believe is the health of the entire organization’s body, and leave out the brain (the PLC :>). Once again, a complete PLC policy and procedure manual is out of the scope of this article. However, I will donate a few random items below to get you started.

1.      Write PLC policies and procedures into your existing maintenance policy and procedures. (SOP)

2.      All personnel working with PLCs will be trained on that PLC equipment.

3.      Backup copies of the PLC programs will be made every 6 months regardless of change status.

4.¬†¬†¬†¬†¬† If a PLC program has been changed …

a.      It will be documented in the software copy, in the printed copy and in the CMMS program.

b.      Copies of the PLC program will be stored on a media more reliable than floppy disk (CD, USB, etc.).

c.      Multiple copies will be stored on laptop, maintenance manager’s office and off site (corporate).

d.      If available, EEPROM will be updated with new changed program.

i.     If outside vendor changes, a-d will be performed by maintenance personnel

5.¬†¬†¬†¬†¬† Future equipment purchases …

a.      A common PLC brand in all equipment will be sought out (Standardization of PLC types)

b.      OEM will be required to provide a descriptor copy of PLC programs in the customer’s native language.

c.      All PLC 110v control voltage will have a line filter on it.

d.      All PLCs will have the backup EEPROM option for zero downtime in some failure modes.

6.      Forcing inputs and outputs on or off shall be treated as a Safety issue. (See safety SOP)

7.      Inputs and outputs shall not be forced on or off with out a clear understanding of complete effect on PLC program and a second opinion.

a.      If forces are installed, they shall be removed with in 24 hours and a more permanent solution found.

b.      All forces should be documented in software and a written log before being enabled.

8.      Online programming is somewhat of a safety risk, normal procedure is to change offline and download to the PLC.

Hope this helps, if you have a specific question you can find me in our PLC discussion area at the PLC Discussion Forum.

Don Fitchett (President)

Business Industrial Network

PLC Training – The best for less

February 21, 2010 Posted by | Electrical, engineering, manufacturing, PLC | , , , , , , , , | 1 Comment


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