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Sunday, February 7, 2016

PLC Program Backup

PLC Program Backup

After reviewing Industry 4.0: Risk I realize there is a lot to do for a manufacturing plant to prepare for Industry 4.0. Good advice is not to be overwhelmed and procrastinate, start somewhere. Start with the PLC Program Backup plan.

PLC Program copies
Only 1/3rd of manufacturing has all PLC Programs backed up!
Even if your manufacturing plant does not go for Industry 4.0 initiatives, insuring your have current backup copies of ALL of your facility's PLC and PAC programs will save you thousands in reduced future downtime. Idealistically you could also insure you have program backups for HMI and SCADA programs too.

The important thing is that you make a PLC program backup plan and start right away. Some improvement is better than none, so do your best and you will still profit from your work. To help out BIN95 offers a free PLC Maintenance Spreadsheet to inventory all your PLCs, checking attributes like last time PLC program was backed up, EEProm burned, battery changed, etc. etc. You can easily add your own attributes to the spreadsheet for example to additionally maintain PACs. (IE: Software require to access, firmware management, module revision numbers, IP address, network management, etc.)

Please, make a plan to back up your facility's PLC/PAC programs today.

Also be prepared, read Industry 4.0: Risk

Don (Follow me on Industrial Skills Training Blog and on Twitter @IndTraining .) Be sure to to stay on top!

Tuesday, November 24, 2015

PLC wiring tutorial: PLC safety circuit

PLC wiring Tutorial:

PLC safety Circuit

RE: CR1, E-Stop wired to PLC I/O





The software used in this video is from http://bin95.com/allen-bradley-plc-programming.htm (PLC Training Certificate Course)



 Don (Follow me on Industrial Skills Training Blog and on Twitter @IndTraining .)Be sure to to stay on top!

Friday, August 28, 2015

PLC Troubleshooting

PLC Troubleshooting - Failure Probability

PLC MTBF does not apply, so much.

(Right click, "Open Image in New Tab", click on image in new tab to view full size)

Failure probability is categorized like this (in order of most likely to least likely).

  1. Mechanical
  2. Electro-Mechanical
  3. High Current
  4. Low Current
  5. Solid State


Environment can be an exception to the general rule.
(Relay card most likely, and MTBF is useless unless solid state, as frequency PLC program activates, dictates failure rate as well as the environment does.)

The above probability guide translate to troubleshooting PLCs as ...


  1. Output Cards
  2. Input Cards
  3. Power Supply
  4. Backplane
  5. CPU (Processor Card)


Environment can change basic order above. Examples: In a foundry, the metal dust causes backplane to fail more frequently. Machining industry, penetrating fluid getting into sensors causes input cards to fail more than output cards because sinks more current than designed to. Wire manufacturing a lot of high voltage insulation testing is going on, CPUs fail more often because control voltage for PLC does not have line filter in series with it.

(More PLC Troubleshooting)


Don (Follow me on Industrial Skills Training Blog and on Twitter @IndTraining .) Be sure to to stay on top!

Monday, July 13, 2015

PLC Training Video Series

PLC Training Video Series ...


PLC training videos
PLC Training Videos
PLC Training videos come in many flavors. From just an ad, to introductory to full PLC training video series course. The PLC training video series below is 6 samples that are very popular. The samples in this series have been selected as samples of the various PLC training video types mentioned previously. Enjoy and share your favorite one.

  1. PLC training video ad: PLC Training Org
  2. Introductory PLC training video: What is a PLC
  3. Experience transfer: PLC Training
  4. Simplifying complex concept: PLC Training PAC
  5. PLC training video series on a single topic: PLC Training - Networking
  6. PLC training video series course: PLC Training Video Course


Don (Follow me on Industrial Skills Training Blog and on Twitter @IndTraining .) Be sure to to stay on top!