Conveyor Rescue
Follow cartons, beams, PLC inputs and rungs. Prove feeding, stopping and the complete transfer.
PLC troubleshooting simulator for conveyor fault finding
PLC troubleshooting simulator.
Test the cause. Prove the repair.
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.
A stopped conveyor is only the starting point. PLCTrain is a browser-based PLC troubleshooting simulator for investigating simulated conveyor faults. Compare sensor inputs, program tags, and ladder logic, choose what to inspect, and test whether your correction proves the repair.
- 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 PLC troubleshooting training, Virtual PLC training, Industrial PLC training. Browse the free PLC troubleshooting guides
What is PLCTrain?
What can you investigate in this simulator?
Conveyor Rescue models three connected belt zones with photoeyes and a ladder rung for each belt. The same complaint can involve sensor alignment, input mapping, or a logic condition. Follow the signal across these layers instead of treating the first stopped belt as the diagnosis. You can inspect and temporarily force simulated signals, then remove the forces before verification. This is an authored troubleshooting environment, not an emulator for uploading a vendor PLC program.
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
Use a PLC simulator to test an explanation.
Establish the expected response.
Compare the operator report with the receiving zone. State whether the belt should feed or wait before looking for a component to replace. An occupied station can correctly prevent movement.
Find the first signal mismatch.
Compare the photoeye's physical input, the tag used by the program, and the rung condition. A tag name alone does not prove that the program reads the intended input.
Verify without temporary overrides.
Remove temporary forces, disable forcing, and repeat the modeled clear and occupied receiving conditions. Complete the transfer; a single movement does not demonstrate both required responses.
Inside Conveyor Rescue
One simulator.
Several possible explanations.
The free Conveyor Rescue demo gives you three investigations on the same connected conveyor. Evaluate whether this PLC fault simulator helps you explain a cause, test a correction, and demonstrate the expected response. Its scope is conveyor signals and basic logic, not every industrial failure mode.
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 inWhat does this PLC troubleshooting simulator include?
It includes a three-zone conveyor, photoeyes, live simulated PLC signals, ladder views, and three fault investigations. You can inspect evidence, make modeled corrections, request coaching, and verify a repair.
Can I upload my own PLC program?
No. Conveyor Rescue uses authored logic and fault scenarios. It is not a vendor PLC emulator or a tool for testing a production program, and it does not connect to real equipment.
Can I force inputs while troubleshooting?
The simulator includes temporary forcing for investigation. Final verification requires removing temporary forces and turning forcing off so the repair is demonstrated with the normal simulated signals.
How does the simulator decide whether a repair works?
The investigation includes repeatable verification checks, including a clear receiving zone, an occupied receiving zone, and the full transfer. Making the conveyor move once is not enough to complete the repair.
Is the PLC troubleshooting simulator free?
The Conveyor Rescue demo is free after account signup, email confirmation, and sign-in. No card, physical PLC, or separate simulator installation is needed.
What should I read before trying the simulator?
The free guides explain photoeye inputs, XIC and XIO instructions, and the difference between a run command and actual conveyor motion. You can read them without an account, then try the investigation.
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.