PLC Troubleshooting 101. Basic Steps to Diagnose and Fix Your Machine

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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[@SteveAxeMeister]

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!

[@FreedomMtnDesigns]

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 Electrical drawing and machine plans are out of date at best and most of our machines have been engineered in Germany and the drawings we do have are mostly in German.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!

[@TimWilborne]

Sounds like you are doing great!

[@dwaynes5983]

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.

[@ortujexinol]

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!

[@dotEmfour]

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.

[@TimWilborne]

I'm glad you agree

[@azael831]

Love you Tim, Thanks for sharing the knowledge.

[@TimWilborne]

I am glad to help!

[@jglez9372]

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

[@TimWilborne]

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

[@john.walley]

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.

[@TimWilborne]

I have a video planned to talk about downtime...including risk from cyber security.

[@pizza4breakfast352]

Mom showing up is soooo wholesome lol. She just loves you so much 😂❤

[@TimWilborne]

She does :)

[@deanbrooks929]

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.

[@TimWilborne]

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.

[@deanbrooks929]

@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.

[@TimWilborne]

Very true.

[@RoboticsSorcerer]

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.

[@TimWilborne]

It is a great career!

[@donijrlast2531]

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

[@TimWilborne]

I'm glad you love our channel! They would usually go to a safety relay. Here is a video on them. kzbin.info/www/bejne/qofRXnWvmM17fKM

[@sparky_murph]

Excellent video, thank you.

[@TimWilborne]

You are welcome!

[@durin5880]

Thank you for this video!

[@TimWilborne]

Glad it was helpful!

[@BretWrightSTUFF]

Thank you for validating, get to know your operator!!

[@TimWilborne]

Yes!

[@fatimamukhtar6062]

Very very informative video. God bless you. Make more videos like this.

[@TimWilborne]

Thanks, will do.

[@darrelljourdan9926]

Good info. Need to have basic maintenance skills in industrial electricity, power drives & transmission, hydraulics, pneumatics, welding, plumbing to be a good machine troubleshooter.

[@TimWilborne]

Well said!

[@mw3blackopsglitches]

Great video Tim love it!

[@TimWilborne]

Glad you enjoyed it

[@jameshussey4900]

Good job 👍

[@TimWilborne]

Thank you!

[@nukeelda]

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.

[@TimWilborne]

Those two years were some of the best training you could have :)

[@nukeelda]

@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.

[@Klincker]

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?

[@TimWilborne]

Good point!

[@stanleykania7184]

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.

[@TimWilborne]

Observe all you can, as it ages, having a good knowledge of how it should operate will be very helpful.

[@DFitz-bk7dj]

The HMI is only as good as it has been programmed! Start with the easiest things and work your way up!!

[@Nicofish2023]

Thanks

[@Nicofish2023]

More of it please

[@TimWilborne]

You are welcome

[@matthewwilliamson1]

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.

[@TimWilborne]

Yes, I have seen it.

[@73jrock]

Tim, I was at a plant over the holidays and in there the downtime cost 20K/min!

[@TimWilborne]

That lines up with what I was researching for a large manufacturer. twcontrols.com/plc-training-part-2

[@user-ro7dy6pv7w]

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.

[@TimWilborne]

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.

[@k50159]

You’re awesome

[@TimWilborne]

Thank you 😊

[@traviscoleman9520]

Schematics? Diagrams? That’s like finding a unicorn in your bathtub. Feel lucky and blessed if you find them.

[@TimWilborne]

Yes!

[@alainmilette6460]

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.

[@TimWilborne]

Too often people put them somewhere for safe keeping then forget about them.

[@Brian_irl]

Is it Destructive (Yes or No) because - if Yes, the process can perform a function (moves) and potentially destroy machine or flesh?

[@TimWilborne]

No, it simply means the instruction that change the data in the tag.

[@mikeg2be]

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

[@TimWilborne]

While our lessons are designed around our PLC trainers, many people use their own hardware. twcontrols.com/plc-trainers

[@fastforu2]

I would be super interested in the troubleshooting trainer !

[@TimWilborne]

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.

[@fastforu2]

@@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!

[@bobbyyoung2831]

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.

[@Dvalle53]

I would love to attend but I live in north texas. What would you suggest?

[@TimWilborne]

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

[@Dvalle53]

@@TimWilborne where can I send my inquiry to?

[@TimWilborne]

The link in the initial reply

[@fatimamukhtar6062]

Would you tell me the issue in this system why not working?

[@TimWilborne]

Use the steps we talk about in this video and you'll figure it out.

[@bigt95nt011037]

How do I get info for your onstte training.

[@TimWilborne]

Here you go. twcontrols.com/plc-lab

[@jessem7966]

I want to get better at using the program as a tool to determine what the problem is.

[@TimWilborne]

That is the topic of this Thursday's livestream at 1pm ET.

[@jamieauriedward9554]

How can I get enrolled in your class

[@TimWilborne]

Submit an inquiry at twcontrols.com/contact

[@JamesGraham1971]

Where is your school located?

[@TimWilborne]

Roanoke Virginia

[@user-qo6pt8hk3b]

❤

[@andyatmosphere]

Where is this classroom at.? Do you offer education.?

[@TimWilborne]

Roanoke, VA, you can find more information at the link below. twcontrols.com/plc-lab

[@scottjones7279]

Missing prints is everyday.

[@TimWilborne]

Yes, I agree...

[@nagrerelax5602]

Where is the tutorial?

[@TimWilborne]

It is in the live section.

[@ortujexinol]

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.

[@TimWilborne]

👍