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Troubleshooting Troubleshooting

As it says in the subtitle, troubleshooting of automation systems becomes the heart of Downtime Reduction School. A school graduate will be knowledgeable in all electrical engineering and associated disciplines. It will include a PLC-based machinery and any industrial process with DCS or other controllers. the actual troubleshooting of any fault in the control system is divided in to the following steps:

  1. Select control system for analysis
  2. Collect all information about the control system
    • Process & Instrumentation Diagrams (P&ID). Create if not available.
    • Electrical Schematics. Create if not available.
    • Control panel layouts with all parts and tags in accordance with Electrical Schematics. Create if not available.
    • Wiring Diagrams. Create if not available.
    • Operator Stations Layouts, Create if not available.
    • HMI Screens. Populate with addresses and registers if not available.
    • PLC Program. Attache descriptions for every rung of logic and function blocks.
    • Obtain Operator and Maintenance manuals. Create if not available.
  3. Create a list (index) of all inputs and outputs including HMI and every remote interlock and permissive.
  4. Break down an overall PLC control programming into reasonable blocks or parts with about 25/25 I/O ratio.
  5. Design and draft Unified Logic schematics for each part in Item 4 and by including all components from Item 2, except manuals by following this set of rules:
    1. An electrical schematic for every part of the control system should be placed on the left side of the drawing
    2. An Input/Output conversion operand should be placed to the right from from the previous item
    3. All real inputs to and from PLC should be placed to the right from the previous item
    4. All outputs should be placed on the right side of the drawing
    5. All operator stations with their PLC addresses or integers should be combined together and displayed next to the image of the OperStation
    6. PLC wiring diagram with all address should be place on the bottom of the drawing
    7. A part of P&ID should be placed on the bottom of the drawing
  6. The final step: convert PLC program into Boolean logic for the selected part of the control system and place it between Item 5.3 and 5.4/5.5.

Please note that Downtime Reduction School offers a crush course on creating Unified Logic diagrams with practical knowledge of Boolean logic representation and PLC logic conversion. Every student will be offered a version of the AutoCAD Electrical with video training for anyone who wants to get practical experience in electronic drafting. AutoCAD Electrical training is prerequisite for getting a Certificate of Completion. Ask for details.

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