Conveyor Rescue
Follow cartons, beams, PLC inputs and rungs. Prove feeding, stopping and the complete transfer.
PLC maintenance training for technicians and maintenance team coaching
PLC maintenance training.
Explain the stop before changing parts.
PLCTrain / Line CallLive machine preview
Earlier Conveyor Rescue recording (member simulator)
This recording shows the separate member simulator, not the Line Call demo above.
Actual Conveyor Rescue gameplay24-second preview
Read what happens in the video
- The box won't move. Where would you look first?
- Compare the sensor signal with the ladder logic.
- Adjust the virtual sensor. Stopped does not mean safe.
- Should it run or stop?
- Now test your fix. Watch the conveyor and logic respond together. Finish every check in the free Conveyor Rescue demo.
This is an excerpt from the real simulation, recorded with a local test account. It does not show a completed assessment. Full verification continues in the trial. Practice maintenance is not real LOTO.
Practice the checks that support a maintenance decision. PLCTrain provides browser-based PLC maintenance training with simulated conveyor faults. Compare a stopped belt, its photoeye input, and the ladder conditions controlling it. Diagnose the mismatch, explain a correction, and demonstrate both feeding and stopping.
- Free web demo: three guided conveyor faults
- Live PLC signals and moving sensors
- Optional hints and repeatable practice
Free web Conveyor Rescue account. Email confirmation required. No card or PLC hardware. Mobile pilot access is separate and by invitation. For a quick look, open Line Call without an account.
3 connected conveyor zones
3 fault investigations
Your pace hints and repeatable practice
Wave 1–2 / Internal mobile pilot / Access by invitation
19 live calls. One troubleshooting method.
The same iPhone and Android experience: a live plant pinned above the tabs and controls. Adjust a sensor and watch the response. Turn the phone sideways for a larger plant view.
Plant networking
Check PLC, HMI, laptop and switch links. Follow ping paths and compare addresses before making a change.
Sensors
Inspect proximity, limit and 4–20 mA behavior, with live plant responses to your adjustments.
Basic electrical
Trace 24 VDC, fuse and contactor-coil paths. Take meter readings before a virtual parts change.
Predict → prove → repair → close. One next action. Fresh proof before closeout. The coach helps you find evidence and refuses to choose the cause. Wrong calls have visible, reversible consequences.
Coming, not included: Conveyor A9–A10 and dedicated PLC-functions, motors/VFDs and safety drills. No public app-store release yet. The browser demos on this page remain separate.
Make the training budget go further
Training shouldn’t end when the trip does.
A week away can introduce new skills. Give technicians a place to keep practicing the decisions they need on the floor—without booking another trip.
One technician. One week away.
- Course tuition
- $5,000
- Travel and stay
- $2,000
- Illustrative total
- $7,000
Before wages, overtime coverage, or time away from the plant. Example budget, not a market average or a quote from a specific provider.
Make troubleshooting practice a routine.
- Practice where you work. Browser demos and the mobile pilot need no travel or physical PLC.
- Make decisions and see the result. Inspect signals, test a repair, and repeat the checks.
- Coach across shifts. Use the same exercise to discuss each technician’s reasoning.
- Budget for the team. Agree access, training scope, and price before enrollment.
The plant responds to your decisions. No countdown or reward for rushing. The goal is an explanation you can support and a repair you can verify.
For maintenance: See what technicians check, where they need a hint, and what to practice next.
For finance: Compare the full team quote with tuition, travel, and coverage costs. Review cost per active learner and evidence of progress.
PLCTrain complements hands-on equipment and vendor training. Learning time still has a cost. This example does not claim $7,000 in savings, superior learning outcomes, or a qualification to work on equipment.
Discuss a team pilotFor maintenance managers and trainers
A method record
you can discuss.
The mobile pilot keeps a local roster of up to 10 seats per site. Review captured names, help requests, wrong-cause choices, forces and repair checks, then discuss the next practice step.
ILLUSTRATIVE SAMPLE / NOT LIVE LEARNER DATA
Supervisor method record
Example learner A Conveyor Rescue A1
Example data only.
Not a qualification or work authorization.
| Method field | Example record | Discuss next |
|---|---|---|
| Captured names | Example learner A / Example site. Local roster attribution. | Confirm who completed the practice. |
| Help and wrong causes | 1 help request. 1 wrong-cause choice. | Which observation changed your mind? |
| Forces and first proof | 0 force uses. First four-condition proof: passed. | Explain the expected response before another check. |
| Repair verification | Four operating conditions and transfers to belts 2 and 3 checked. No active forces at closeout. | Repeat independently and compare the method. |
The next useful conversation
Which check changed your mind?
Ask the technician to explain the evidence behind the change, then try another call without help. A completed simulation is a starting point for coaching, not a qualification.
- Help requests
- 1 example
- Wrong-cause choices
- 1 example
Discuss a pilot for your team. Agree access, scope and price before enrollment.
Discuss a team pilotLogic Lab / Drill Studio
Write the rung. Watch the conveyor respond.
Build ladder logic from scratch, run two connected conveyors, and trace the sensor signals. Create your own drills, test the machine behavior, and replay each scan to see why a circuit passed or failed.
Open Logic LabStart with a blank rung or a guided lesson. See the effect of every circuit change on the machine.Open Drill StudioTry a conveyor drill or author one with a brief, hints, photoeye faults, and machine tests.
Free to try. Circuit drafts and authored drills stay in this browser; export a copy to share your work.
Free guides / No account needed to read
Make the signals make sense.
The belt is clear. Why does the photoeye say blocked?Understand a blocked photoeye input on a clear conveyor. Compare the sensor, physical input, PLC tag, and ladder logic using PLCTrain simulation examples.XIC vs XIO. Read the bit, not the name.Learn when XIC and XIO instructions are true, why green does not mean a sensor is healthy, and how a blocked photoeye affects a conveyor rung.Run command: ON. Conveyor: STOPPED. Both can be true.Understand the difference between a PLC run command, output command, and actual conveyor motion. Learn to explain why a requested start may not move a belt.
Explore Industrial PLC training, PLC training, PLC troubleshooting training. Browse the free PLC troubleshooting guides
What is PLCTrain?
What can a maintenance team practice here?
A run request, a PLC output command, and actual conveyor motion describe different things. Practice separating them before choosing a repair. In an observed session, a trainer can ask which condition prevents feeding, what evidence supports that explanation, and which test would disprove it. Review the individual practice record to discuss hint use and verification. The sample skills report illustrates a possible coaching conversation; it is not an available live team dashboard, a preventive-maintenance system, or a workplace qualification.
Inside Line Call / no account needed
"The box will not feed."
Where would you look first?
The space ahead. The photoeye. The PLC input and rung. The motor output.
Choose your own starting point. Compare the machine with the signals, try a likely cause, and test what changed. A wrong lead is recoverable.
Moving once is not enough. Prove that the line feeds when clear and stops when the receiving station is full.
01 / 03
Practice a maintenance investigation through handover.
Describe the operating condition.
Use the operator's complaint and the visible receiving zone to state the expected behavior. Explain whether a stopped belt is an appropriate response to a full station or evidence of a mismatch.
Separate the request from the response.
Compare the run request, photoeye state, named input, and ladder condition. Identify what supports the chosen correction instead of treating a replacement component as proof of diagnosis.
Explain the proof of repair.
Repeat clear and occupied receiving conditions and complete the transfer. In the debrief, describe what changed, what each check demonstrated, and which assumptions still needed coaching.
Inside Conveyor Rescue
A shared machine.
A useful maintenance debrief.
Use the three Conveyor Rescue investigations to observe evidence selection and repair verification. The demo concentrates on sensor and PLC signal reasoning. It does not reproduce every drive, electrical, mechanical, or safety-system fault found on a real production line.
The box will not feed: call 1
Same initial complaint. Ask what changed, inspect the evidence, and explain the repair.
You practiceObserve. Diagnose. Prove.
The box will not feed: call 2
Same initial complaint. Ask what changed, inspect the evidence, and explain the repair.
You practiceObserve. Diagnose. Prove.
The box will not feed: call 3
Same initial complaint. Ask what changed, inspect the evidence, and explain the repair.
You practiceObserve. Diagnose. Prove.
You control the pace. Use the tools, ask for a hint, and repeat each repair check.
Line Call progress stays in this tab. Refreshing starts a new session. Member training saves progress to your account.
Who is it for?
New to maintenance?
Already on the tools?
Start here.
Future technicians & students
See what troubleshooting involves. Connect unfamiliar PLC terms to a machine you can watch and control.
Working maintenance technicians
Practice checking the evidence before changing parts or code. Repeat a fault and see how your decisions affect the line.
Maintenance managers & trainers
Try the demo yourself and decide whether this approach fits your team. Use a scenario to talk through what a technician would check and why.
A clear starting point
Try a fault.
Choose your training scope.
Available in the free demo: conveyor troubleshooting, photoeye alignment, input mapping, and basic ladder logic.
In the mobile pilot: 19 live calls, the same iPhone/Android plant behavior, proof gates and a local 10-seat method record. Dedicated PLC-functions, motors/VFDs and safety drills remain Coming.
For team access, agree the learners, training scope, reporting, and price before enrollment. Email training@plctrain.com to discuss your goals.
Your first callout is waiting
Try fixing it yourself.
Start Line Call immediately. Inspect the receiving photoeye, trace the input and ladder logic, then prove the repair with optional hints. Existing member training remains available through sign-in.
Try the public Line Call previewFree in your browser. No account or approval needed for Line Call.
Already have an account? Sign inWho is this PLC maintenance training for?
It is for maintenance technicians, students entering maintenance, and trainers observing diagnostic decisions. The demo connects a familiar conveyor complaint with sensor evidence and basic PLC logic.
Does this teach preventive maintenance schedules?
No. Conveyor Rescue focuses on diagnosing a modeled conveyor fault and verifying its correction. It does not provide preventive-maintenance schedules, asset management, or equipment-specific service procedures.
What should a trainer observe during practice?
Ask why the learner selected each check, how the physical input relates to the program tag, and whether the final tests demonstrate both feeding and stopping. Discuss any coaching prompts needed along the way.
Are team dashboards or employer reports included?
The demo includes individual practice records. The manager report shown on the page uses illustrative sample data; it is not a live team dashboard or an automatically delivered employer report.
Does completing the demo authorize work on machinery?
No. It records practice in a simulation. Real equipment work still requires the relevant training, authorization, documentation, and site procedures.
How can we try the maintenance training?
Create a free account, confirm the email, and sign in to Conveyor Rescue. A trainer can observe an investigation and discuss the decisions afterward. No physical PLC or card is needed.
How does the training-cost example work?
The example adds $5,000 in tuition to $2,000 in travel and stay for one technician: $7,000 before wages or coverage costs. It is an illustrative budget, not a market average or a savings claim. Compare your actual course costs with a PLCTrain team quote and the training scope you need. Simulation complements hands-on and required vendor training.
Which practice needs an account?
The public Line Call repair preview and beginner lessons need no account. Line Call resets on refresh; lesson drafts stay in this browser. The separate free Conveyor Rescue demo includes three guided faults and account-saved progress: create an account, confirm your email, then start. No card or physical PLC is required.
Want guided practice with account-saved progress?
Create a free Conveyor Rescue account for three guided fault scenarios, hints, and video guidance. Your public Line Call session stays separate and does not transfer.