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July 20, 2010 A Penton Media Publication Vol. VI No. 14



CONTENTS
You and IR, Part 6

Electrical Troubleshooting Quiz

Troubleshooting PLC Digital Output Modules, Part 2

NEC in the Facility

Safety

Call for Papers


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This twice-a-month
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MRO Insider addresses topics such as:

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  • National Electrical Code® on the production floor
  • Safety procedures and programs
  • Troubleshooting techniques
  • Equipment maintenance and testing tips
  • Managing motors and generators
  • Trends in training and education
  • Managing energy use


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    Maintenance
    You and IR, Part 6
    Are you fully exploiting thermographic technology? In case you’re not aware, here is a partial list of uses:
    • Monitor transformers. For dry types, check the vent. For oil-filled types, check the reservoir. For both, check the connections.
    • See emerging breaker problems. Breaker testing is essential, but frequency is low because testing requires removing breakers from service. Fill the "condition knowledge gap" with thermographic testing.
    • Motors. Problems with windings, bearings, vents, connections, and gear boxes show up on thermographic images.
    A huge advantage of thermography is the speed at which you can do it. For example, scanning an entire panel at once with a thermographic camera takes much less time than individually testing breakers.



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    Repair
    Electrical Troubleshooting Quiz
    Your factory has an automated shipping dock system, with 10 bays. A conveyor system feeds 200-lb product boxes to a chute for each bay. When the chute for a bay is full, the indicator light outside the bay door turns from red to green so truck drivers know which bay to pull up to.

    You come in on second shift to find a note saying the Bay 6 light never turns green when the bay is full. The tech replaced the analog output module in the morning, solving the problem. However, just before quitting time, the problem came back.

    What's your next step?

    Visit EC&M's website to see the answer.


    Troubleshooting PLC Digital Output Modules, Part 2
    In our previous issue, we said a digital output module could be tested by using the PLC logic to force the output on and off then and observing the module’s response. If the module doesn't respond, replace it.

    But what if the replacement module doesn't respond? Test both modules in a known working loop. If either one works there but not in the loop that's faulty, then the problem obviously isn't the module. It's in the backplane, cabling, or some other area between the module and the PLC logic.

    To read more on this story, visit EC&M's website.


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    Operation
    NEC in the Facility
    Question: What are a dozen things you can do to vastly enrich your understanding of the NEC?

    Answer: Work through the 12 examples in Annex D of the NEC.

    The answer is a bit misleading, though. For one thing, there are actually more than 12 examples. The D1 through D12 examples include ones such as D2(a), D2(b), and D2(c). Furthermore, most of these are for residential calculations. Don't let the residential aspect throw you, however. Those residential examples provide you with a good way to work through NEC concepts you'll use in the facility.

    To read more on this story, visit EC&M's website.
    Safety
    Aerial lifts are tremendously useful in any plant with high ceilings, because they allow you to reach lights, security devices, sprinkler heads, and anything else well above the floor. If you have tall production equipment, overhead conveyors, or signage to deal with, an aerial lift beats a ladder almost every time.

    However, it can also be dangerous. To protect yourself:

    • Move the lift only with the platform locked in the travel position.
    • Ensure that only qualified personnel (as defined by OSHA) operate it.
    • Test the controls before using. Most lifts have two sets of controls; test both.
    • Attach your lanyard to the basket — not to pipes or adjacent structures.
    • Don't stand on the basket rails.

    Show & Events
    Call for Papers
    Interested in sharing your industry expertise? Speaking opportunities are still available on the Electric West 2011 conference program. The conference will take place February 22-24, 2011, at the Long Beach Convention Center in Long Beach, Calif. Contact Florence Torres, Conference Director, for more information on the event, or submit a proposal online by visiting the Electric West show site.

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