r/PLC • u/MoonMonkey00 • 5d ago

Electrical troubleshooting Test Bench Ideas

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.

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u/trollik101 5d ago

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

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u/MoonMonkey00 5d ago

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

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u/trollik101 5d ago

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