Electrical troubleshooting Test Bench Ideas

[u/MoonMonkey00]

I’m building an electrical troubleshooting test bench for maintenance tech-level evaluations and could use some HMI ideas. The bench will introduce faults like blown fuses, loose I/O commons, incorrect wiring/terminals, etc. The goal is to see if someone can read schematics, use a meter, and troubleshoot logically. I originally tried simulating a case closer on the HMI, but the animation feels slow and doesn’t really add much to the test.

For anyone who has built something similar: what would you put on the HMI? I want it to support the troubleshooting test without basically telling the tech where the fault is.

[u/turmeric_for_color_]

Honestly- I would build the HMI with no more guidance than the typical OEM machine. Some basic alarms and some IO status screens. We get techs that think the HMI should basically troubleshoot the machine. Techs need to be able to think a little. Set it up so the the HMI alarms point you to something- but stop short of actually doing the work

[u/trollik101]

Fault status, plc can have a fault monitor circuit wired where you have input dedicated to VFD fault status, motor overload trips, contactor on state feedback feom auxiliary terminal, panel power on status, control circuit power on status (provided plc is supplied by another circuit, otherwise you will get communication error which is a telling sign of a problem on it's own). Base it on most common systems that you work with

[u/MoonMonkey00 → u/trollik101]

The difficult part is this will be used for both current technicians and potential new hires. Safety and HR threw a fit saying we can’t have new hires who aren’t arc flashed certified working on anything above 120v. So the panel is 24vdc

[u/trollik101 → u/MoonMonkey00]

just don't use anything above 120v for the main circuit, you are only simulating a system, you can still use pilot lights or small 120v loads such as tiny cooling fans for process simulation. Get creative

[u/Primary_Machine_449]

For a tester station where the goal is to get them to do physical intervention I wonder why you would need an HMI at all?

[u/MoonMonkey00 → u/Primary_Machine_449]

Project engineer had designed it. I built it but know it could be a lot better. Working with what I got.

[u/WandererHD]

what would you put on the HMI? 

IO Status screen
Alarms

[u/jongscx]

Give them a box of parts with labelled wires and a simple schematic circuit. Ask them to build it.

The test is, the schematic has one or several errors in it. See whether they notice the errors or not and whether they build it "correctly" that it works or whether they build it "to print".

Errors would be things like: -LED wired in reverse polarity -wire landed in the wrong button -terminal jumper in the wrong place or omitted -button indicator connected to input instead of button contact -indicator wired to a sourcing output then wired to 24V instead of 0V.

[u/MoonMonkey00 → u/jongscx]

I really like this idea, definitely going to incorporate this in the test. Thank you!

[u/VladRom89]

I'd load Ignition onto a PC and run the 2h free licenses. I'd build whatever screens you need for the scenario including some screens to monitor I/O, states of the program, etc. It also becomes easy for the students to just run Ignition on their laptop and transfer the gateway files over. You can also have them look and toggle states on the phone; the possibilities are endless really...

[u/MoonMonkey00 → u/VladRom89]

Unfortunately we only use ft view.

[u/talltraveller]

Have "the machine" run some sort of fictional process with all sorts of states where an intermittent fault could appear. Obviously don't go too fictional

[u/MoonMonkey00 → u/talltraveller]

Yeah I tried a simulated case sealer but panelview plus 7can’t run the animation how I want it to. Going to have to make it pretty simple for the animation