PLC Troubleshooting 101. Basic Steps to Diagnose and Fix Your Machine
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- เผยแพร่เมื่อ 20 พ.ย. 2024
- Diagnosing machine faults is something that gets easier with experience, but if you follow these simple steps, you'll find the problem every time.
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No matter what you are troubleshooting, DON'T just start "stabbing" at problems. Every test or attempt should have an expected result. That means you have to think it out before you do it. And it's like chess, be ready to perform the next move based on the results of the first move. Easy fixes should come in 1 to 3 moves because you expected results have led you to a logical conclusions. I call it triangulating on the problem. And while really good operators will give you really good insight, to be honest it's rare and too many disappear the minute you show up and if you do get something out of them it may be completely false or they are covering up a stupid mistatke they made. But never forget RULE # 1 !! Check all the power supplies, fuses and circuit breakers FIRST before starting to troubleshoot anything. You don't even need prints for that most of the time. Suddenly you're a genius!
Rule #1A: Check and provide PROPER grounding.
You are so correct about down time! I'm and engineer converted to cybersecurity and I have such a hard time explaining the importance of 0 unscheduled downtime and that maintenance windows are extremely tight. I keep getting "just update the firmware." Explaining it doesn't work that way to IT security professionals can be difficult. I'm going to start sending people to this channel! So good! Please keep this up.
I have a video planned to talk about downtime...including risk from cyber security.
Timestamp: 5:59
I’ve been working in a manufacturing plant for about 6 weeks at this point. When a machine breaks - I start by asking the operator to describe in detail what happened and if they noticed anything out of the ordinary before the incident. I also ask them what they have done since it happened. This gives me a starting point to begin looking for the issue.
Electrical drawing and machine plans are out of date at best and most of our machines have been engineered in Germany and the drawings we do have are mostly in German.
It’s sink or swim baby!
Sounds like you are doing great!
I found out when you ask the operator I never get a answer. They messed up and dont want the blame same goes for customers.
Usually the operators will tell me right away what the issue is before I even start to ask. I work with a great bunch fine folks!
Sounds exactly like the plant I’m at, got me trying to read German just to find a part 😂
German is fine, good luck with Chinese 😂
I train control techs and your advise around 8:40 is spot on. Having the techs trust, or even just their initial buy-in, helps you to get a very clear picture of the block.
I'm glad you agree
As someone new to this industry with electronics background it's been an interesting ride. In this plant prints are the unicorn. it comes down to troubleshooting skills. Operators are you friend, until you piss them off. I bring in every operator in to find out what the machine was, or not, doing when the error showed up. They know the machine way better than I do. I have to ask questions otherwise I'll go in circles. Troubleshooting is a true acquired skill.
Most times, the operator is also appreciative of you asking. It make them feel valued in the troubleshooting process which will make them be more observant later.
@TimWilborne very much so. Just happened last night where I had 3 operators involved in troubleshooting. They thanked me numerous times as a result. Customer service is really the topic here that seems to be overlooked by some folks.
Very true.
Thanks Tim. That was a great video for me. I am beginning to troubleshoot with PlC and I do get lost a lot.
I will continue practicing.
If there is anything I could set up myself I probably could at work
You can do it! If you have some spare parts, open them up and start practicing. Also, you can get through the counter lesson of this course with the free version of CCW and the simulator, then you can consider options of investing in hardware.
courses.twcontrols.com/courses/allen-bradley-micro800-plc-training
Ive been wiring up plcs for the last year and still have a long way to go to feel confident. The funny thing is I have an associates degree in industrial robotics. Now Im just looking for work since I just graduated.
It is a great career!
Love your Channel !!! when an e stop is pressed if there are multiple estops they will usually cuts power to the inputs or out
put or both
I'm glad you love our channel! They would usually go to a safety relay. Here is a video on them.
th-cam.com/video/tVn-BychHFA/w-d-xo.html
Mom showing up is soooo wholesome lol. She just loves you so much 😂❤
She does :)
Good info. Need to have basic maintenance skills in industrial electricity, power drives & transmission, hydraulics, pneumatics, welding, plumbing to be a good machine troubleshooter.
Well said!
I started just after automation trade school in Tysoon plant 1500 people plant with most new mashines (Spider robots use pc as plc ,one motion motors as servo can be used ,Fanuc robots,studio5000 mostly used also other plc's ,still have old type mashines too but small size, and type network-cloud based operations as a scales and soo on...) we had to learn 80% of mashines how they operate soo first 2 years was hell but now I got a lot of skills for 3 years in the field soo we get call's from mechanics and production but not too much issues overall because they know mashines now to point out what it doesn't doo, it is good experience.
Those two years were some of the best training you could have :)
@TimWilborne yes Tim now we cut and change a lot of conveyor systems where we have to change programs too ,soo overall troubleshooting is now comfortable,even it is new place we still have older machines with no drawings but you found a way with logical approach.
Very good points! Been to multiple service calls this week and the only thing I would add is asking maintenance upon arrival what parts or wires have you guys changed/modified?
Good point!
Knapp system here at Dimond drug, Indiana Pennsylvania is a new fulfillment center. Nothing ever breaks down. We maintenance shuttles, tote jams, reset a breakers.
Observe all you can, as it ages, having a good knowledge of how it should operate will be very helpful.
Operators can be valuable if they are good operators. I have lots that dont care or dont know. Being the rookie controls tech i get a lot of crap from the maintenance techs and lately it has come down to always being a " controls issue", because they dont want to bother doing the job.
Similar to what I said about operators, it is all about building relationships. You are young and talented but they are old and experienced. They need to listed to you but you have to respect them.
Thank You So Much Tim ! , Im Trying to Get as much Information so i can Troubleshooting Equipment with Studio 5000. Most of the Time it's something simple but I need to Prepare myself for the Technical Part. My Regards , Greetings to all.
I'm glad you found it helpful
Thank you for validating, get to know your operator!!
Yes!
Love you Tim, Thanks for sharing the knowledge.
I am glad to help!
Have you seen the remote setups that yaskawa have for their sigma 7 drive training. A remote plc training setup like that might be interesting.
Yes, I have seen it.
Schematics? Diagrams? That’s like finding a unicorn in your bathtub. Feel lucky and blessed if you find them.
Yes!
I once wired a panel, slipped the diagrams in the little plastic sleeve once I was done. Some ages later get called to work on that cabinet.Thrilled cause I know for a fact I left the schematics in the cabinet door. For some reason someone must have felt they belonged elsewhere cause they were gone. I hate people sometimes.
Too often people put them somewhere for safe keeping then forget about them.
Tim, I was at a plant over the holidays and in there the downtime cost 20K/min!
That lines up with what I was researching for a large manufacturer.
twcontrols.com/plc-training-part-2
The HMI is only as good as it has been programmed! Start with the easiest things and work your way up!!
Is it Destructive (Yes or No) because - if Yes, the process can perform a function (moves) and potentially destroy machine or flesh?
No, it simply means the instruction that change the data in the tag.
It must be nice to have access to plc program. Working 2nd shift most of the time we don't have access to that. So I always ask the operator what is it not doing, than go to what ever makes it do what ever it was supposed to do. And work back from there.
Yes, sometimes you have to work with what you have. Hopefully they'll get some of your 2nd shift folks some PLC training
TiM WHERE ARE YOU LOCATED? HOW DO I COME TO YOUR SCHOOL? WHERE CAN I FIND A SIMULATOR?
Here you go.
twcontrols.com/sign-up-for-tim-wilbornes-plc-training
Excellent video, thank you.
You are welcome!
Thank you for this video!
Glad it was helpful!
Very very informative video.
God bless you.
Make more videos like this.
Thanks, will do.
I would be super interested in the troubleshooting trainer !
I may revisit it but similar to our machine trainer, it has more to do with getting you in the right mindset for troubleshooting than the actual hardware.
@@TimWilborne i definitely agree. troubleshooting is a different animal. I did a lot of online training to learn to program. but troubleshooting was something else for me at first. it’s definitely something completely different and a skill that’s priceless to have when working on unknown machinery. and now have a troubleshooting trainer to practice at home would just make you feel 10x more confident!
Great video Tim love it!
Glad you enjoyed it
Good job 👍
Thank you!
First thing I ask is...Has anything changed...Who worked on this last...ask operator what's happening...what operator is working...do a visual look around...then start testing with meter etc.
I want to get better at using the program as a tool to determine what the problem is.
That is the topic of this Thursday's livestream at 1pm ET.
Divide and conquering. Power. No power
👍
Hey Tim I just signed up for some of the online lessons and the very first link is not loading, also do I need your trainer for these lessons? Thanks
While our lessons are designed around our PLC trainers, many people use their own hardware.
twcontrols.com/plc-trainers
Where do you livestream at ?
At our training center in Roanoke Virginia
I’m an HVAC guy learning PLC’s I’ve worked on ABB freq. drives with 99 inputs. And opened panels where a jumbled bowl of spaghetti falls out. Q, why are the wires always Red? 😂
😁
I would love to attend but I live in north texas. What would you suggest?
Our two most popular states are Texas and California so don't let that hold you back. Send an inquiry in and let's see what would be best for you.
twcontrols.com/contact
@@TimWilborne where can I send my inquiry to?
The link in the initial reply
How do I get info for your onstte training.
Here you go.
twcontrols.com/plc-lab
When everything else falls into water, get the user's manual 😂
😁
Thanks
More of it please
You are welcome
Would you tell me the issue in this system why not working?
Use the steps we talk about in this video and you'll figure it out.
How can I get enrolled in your class
Submit an inquiry at twcontrols.com/contact
Missing prints is everyday.
Yes, I agree...
i want to work at your workshop
😁
Where is your school located?
Roanoke Virginia
Where is this classroom at.? Do you offer education.?
Roanoke, VA, you can find more information at the link below.
twcontrols.com/plc-lab
FROM YOU WHERE
Roanoke VA USA
You’re awesome
Thank you 😊
Where is the tutorial?
It is in the live section.
How can I join that classroom sir?
You can learn more at the following link
twcontrols.com/plc-lab
❤
Trust me, in the food industry, operators know more than maintenance on how to lead where the issues are...of course they need maintenance to go in controls and thumb there brains out...but if you as tech dont know what you r looking for, you are causing DT.
👍
That’s because they are on the line 8hr of day so operators should kno n be able to explain what’s wrong so maintenance can fix it