Controls Trainer Level 2 — Troubleshooting
Back to Levels

Level 2 — Troubleshooting Bench

Service call CT‑401: the packaging conveyor faulted and won't restart. Diagnose it with a real Fluke 87V — set a function, pick up a lead, then probe the control terminals to find where the 24 V control voltage is lost. Every terminal is live; only the right ones reveal the fault. Then lock it out and make the repair.

FLUKE 87 V TRUE RMS MULTIMETER ⚡ AC DC Auto •))) MIN MAXRANGEHz % REL ΔHOLDAuto AmA µACOMVΩ 10A MAX400mA CAT III 1000VCAT IV 600V

Meter

Function: OFF — leads in COM + VΩ (voltage/resistance).
Click a lead on the meter — red at the VΩ jack or black at COM — to pick it up, then click a terminal on a device to land it.

Control‑panel test points conveyor dead

Swipe sideways to see the whole panel.
Land the leads on the control-circuit terminals and trace where 24 V disappears.

How this panel is fed: 120 V control power (X1/X2) comes from control transformer T1 (480:120 V), mounted above this panel and fed from the load side of the main disconnect through its own primary fuses. That is why opening the main disconnect also removes control power. The incoming protective (ground) conductor lands on the copper ground bar under the main disconnect; the bar is bolted straight to the backplate (BOND1/BOND2) and the backplate is bonded to the enclosure. Wires are identified by the number on the sleeve at each end; runs inside the covered wireways are hidden. +24 V and 0 V are distributed on jumpered terminal strips TB1 (+24 V) and TB2 (0 V): the supply feeds each strip once (FD) and every device has its own screw — one conductor per terminal. This is a training drawing: always follow the device manufacturers' terminal ratings and your site's electrical drawings.

Lockout / Tagout & Repair
Main Disconnect: ON
Lockout station take a hasp take a hasp take a hasp take a lock take a lock take a lock take a lock take a tag take a tag
1
Verify zero energy
2
Replace the faulted component
3
Remove LOTO
✔ Conveyor CT-401 restored — replaced under lockout, zero energy verified, line proven running. Service call closed.

Packaging Conveyor STOPPED

packaging conveyor
Motor M1 de-energized — belt will not move.
Diagnose, lock out, replace the faulted part, then prove the line runs.
Allen-BradleyPanelView Plus 7
Packaging Line 3Conveyor CT-401
—
—
▶
RUNConveyor Running
■
STOPReady / Idle
⚠
FAULTActive Fault
—
—
I/O Status
Inputs (I)
I:0/0Cycle Start
I:0/1Stop (NC)
I:0/2Photoeye
I:0/3M1 Fault
Outputs (O)
O:0/0Conveyor Run (M1)
O:0/1Fault Light
⚠ Alarm Summary
TimeTagMessageState
⌂ Home
✋ Manual
↻ Auto
▤ I/O
⚠ Alarms
Website Design & Development by John Clore