Troubleshooting Industrial Electrical Circuits

Electrical Troubleshooting Simulator Overview:

The free online version was designed as a prototype for the new online industrial electrical troubleshooting certificate course. In the meantime, it serves as an introduction to our downloadable industrial electrical troubleshooting certificate course. There are three modes of simulator operation. The user starts out in 'Explorer' mode and after completing the 6 familiarization steps and a review of our certificate course offer, the simulator automatically unlocks the 'Skill Test' mode. After the user troubleshoots and repairs the 10 electrical problems in skill test mode, the 'Bonus' mode is unlocked. In the bonus mode, users can retake any or all of the 10 skill tests as much as they like. Other electrical troubleshooting simulator features can be unlocked along the way too, like the mode switch on VOM.

NEW Version 4.1: April 2023 - New game level Rando Mode added. Rando mode runs off the new 4.5 fault generator engine that generates every possible fault for a circuit. Also added a new interactive schematic ('Cheatsheet') as a bonus for the Rando game level. Added two more modes to the meter mode switch, enhanced GUI, as well as added some more features such as reset Rando faults option.

Simulator Modes:

While in the explorer mode, the user can monitor minutes spent exploring. If the user spends at least 10 minutes exploring, the user gets 20 extra points. Explorer mode is feature-rich to make learning the simulator easy. In the skill test mode, the user monitors True Downtime Cost® (TDC) as well as points. Have fun, please share https://bin95.com/industrial/electrical-troubleshooting.html with your friends. The more users share this free training tool on social media, the more we will be encouraged to expand on it.

Simulator Explorer Mode:

The first time user is in explore mode, the simulator system terminal walks the user through 6 familiarization steps. Hovering over objects on the screen gives additional help. At any point in time, users can just explore the app. While in this mode, time spent exploring is displayed. The score varies for each step completed. Completed Explorer steps are reset if the user refreshes the industrial electrical troubleshooting simulator web page. While in explorer mode, options below the Next Step button will include 'Show Step Status' to give the user even further help in completing each step with the highest score possible. The 'Show Test Spots' option puts colored squares around each test point should users have difficulty dropping electrical test leads on test points when they are first learning to use the industrial electrical troubleshooting simulator.

Simulator Skill Test Mode:

The first time user is in Skill Test mode, the simulator system terminal walks user through 10 industrial electrical troubleshooting simulated electrical problems to solve. Score is based on best procedures used, equipment fixed and time taken. (TDC) Replacement of a Part when not needed, results in a lower score. Simulator options below next step button automatically change from 'Show Step Status' to 'Goto Explorer Mode'.

Simulator Bonus Mode:

The Bonus Mode is unlocked by the user completing all 6 steps in Explorer Mode and all 5 Skill Tests. In the bonus mode user can retake any or all of the 5 skill tests as much as they like. The progress report lets the user select or de-select the skill test completed. If the user uncheck a skill test, tapping the 'Next Step' button introduces that electrical fault for the user to solve again. Bonus mode also allows users to switch back and forth between explore and skill test modes.

Simulator Rando Mode:

This newly added game level, 'Rando Mode', is unlocked after solving all Skill Test Bonus mode electrical faults. In the Rando mode, the battery/score meter function is reversed for a race against time. The battery/score meter starts out full with each electrical fault, your goal is to solve the fault before the battery level reaches 50% of the charge left. Just like completion of the Skill test level unlocks bonus mode, so does completing the Rando Mode. Upon completion, All three levels are unlocked so you can do any of them again, as much as you want.

Also, the unique 'Cheatsheet' is unlocked. The Cheat sheet is a live schematic that shows voltages and currents while allowing you to switch the circuit on and off the industrial electrical circuit.

Simulator App System Terminal:

The troubleshooting simulator System terminal is the user's interactive guide while using the simulator. There is an on-off switch above it should the user find the virtual instructor's assistance is no longer needed.

Tapping (clicking) the 'Next Step' button below the terminal, updates the system terminal message. If the user is not sure what to do next, the user should click the 'Next Step' button and the system terminal will tell the user where they are at in the explorer steps or skill test, and what is next.

Game App Score:

In explorer mode, each step can score 10-20 points in total. Spending 10 minutes or more going through 6 steps and exploring, results in an additional 20 points. The total possible score for all 6 steps combined is 100 (100%). The skill Test score is based on the best procedures used, if the equipment is fixed and the time taken. (TDC) Replacement of a Part when not needed, results in a lower score. Each Skill Test can result in up to 20 points (20% of score) for a total of 100 possible points (100%).

The battery works its way up to green (full charge) in 10-point increments, starting with orange at the bottom. The actual score will also show below the battery. If the user attempts to work on devices without LOTO first, all points are lost.

Electrical Troubleshooting Downtime:

In the skill test mode, the electrical troubleshooting simulator does not show downtime but instead shows True Downtime Cost® (TDC). Seeing true dollars lost instead of time helps to motivate users to quickly find faults and repair. It also helps display extra true cost of replacing parts that didn't need be. Each part replaced or screws tightened adds 10-20 minutes to downtime, which times the TDC per hour, equals increased downtime cost. The goal of the troubleshooting game app is for the user to score as high a score as possible while minimizing downtime costs. The game is designed to facilitate an improvement regardless of which goal the user may focus on.

Electrical Troubleshooting Downtime Cost:

This troubleshooting simulator uses True Downtime Cost® (TDC). You can click on that link to learn more about how TDC is calculated. By default, the true downtime cost per hour is set at $10,000, which is the average cost of a manufacturing bottleneck machine being down. Users can click on TDC to change the true cost per hour to an amount used at their own company.

How to use Electrical Diagram:

Below the simulator system terminal is a button to open the electrical diagram for the equipment user troubleshooting. Located at the top and middle of the electrical diagram are the buttons 'Close' and 'Print'. Users can drag electrical diagrams anywhere on the screen so it's not in the way while troubleshooting electrical problems.

How to use Electrical Cheat Sheet:

After users fix all electrical faults in Rando Mode, the electrical Cheat Sheet is unlocked. The user opens by clicking on the warning signs on the meter.

The Electrical Cheat Sheet is a standard schematic made to be interactive and simulate the circuit right in the schematic. It also has the added advantage of showing currents, to better help users troubleshoot electrical faults. Experience live voltages and currents based on working or faulted circuits when the user taps the green or red buttons. See what it looks like by tapping the picture below...

Electrical Troubleshooting Simulator Options:

While in explorer mode, options below the next step button will include 'Show Test Spots' and 'Show Step Status'. The 'Show Test Spots' option puts colored squares around each test point. The 'Show Step Status' shows users the current step they are in and what required familiarization or troubleshooting tasks need to be completed in order to move on to the next step. Options change from 'Show Step Status' to 'Go to Explorer Mode' automatically when the user switches to Skill Test mode. When a user checks 'Go to Explorer Mode', the electrical troubleshooting simulator automatically switches mode. When the "bonus" mode is earned by the user, VOM yellow Mode switch is activated enabling the user to toggle back in form between the two modes.

In Rando mode when the user completes the first Rando round, the user will see "Reset Rando Faults" appear in the simulator options area.

Lockout Tagout Training:

Safety first. The 6 Lockout Tag-out (LOTO) steps are mandatory. It is designed to guide users through the steps. Due to repetition, after a while, the steps become second nature... The user only needs to create a tag once; making it slightly more easy hands-on training, than in the real world. Users will find the simulated hands-on LOTO approach is more effective than just reviewing a presentation and answering a written test.

Changing a part or tightening screws without lockout tag-out first results in a game over. The user will have to refresh the browser and all points are lost. Next time the user has to heed the warnings that pop up and lockout tagout first.

Troubleshooting Note Pad:

The troubleshooting notepad is a dual-functional one. There are notes for the user, and the user can save/open their own notes. When the user has a troubleshooting fault to solve, they can find notes on equipment breakdown from the operator in the note pad too. Additionally, when the user starts LOTO processes, the required steps appear on the notepad. When the user opens the progress report, it appears on the notepad. Tapping the company logo on note pad opens this help page.

Game Progress Report:

The game progress report while in the explorer mode or skill test mode, indicates what mode the user is currently in. When the user unlocks the Bonus Mode, the skill test area will become editable, so the user can check and uncheck the skill test the user wants to take again. After the user makes sure the test they want to take again, is un-checked, the user taps the next step button to solve the electrical fault present.

How to use Volt Ohm Meter:

In the free online electrical troubleshooting simulator version, only voltage is displayed (120v). The full online version will eventually read voltage, amps, resistance, and DC and have a built-in oscilloscope. The meter itself, as well as leads are independently draggable. The off switch automatically retracts both meter leads. The yellow Mode switch switches the electrical simulator to Skill Test Mode. Rando mode was added to the mode switch and warning signs become a cheat sheet button after completing Rando mode the first time.

Part Replacement Simulation:

In the free online simulator, right-clicking on a device gives the user two options, replace the part, or tighten the screws. In the full online version, additional options may be available. During the process of replacing a part, the user is tightening screws automatically. So if the fault is a loose wire and the user replaces the part, the user still will have fixed the fault. Users would just have wasted more time and money than need to be. If the user replaced a part to fix a problem, when all that was needed was to tighten screws, fewer points are earned.

Electrical Problems to solve:

Possible electrical problems and fault types that could be present in the full online version can be many. IE: loose wire, the bad part, wrong fuse, short, open, intermittent, etc. Environmental elements that could be involved are heat, vibration, water, and bad line voltage. Senses required to troubleshoot may be sight, hearing, touch, and smell; so the electrical troubleshooting simulator uses innovative ways to simulate those senses. With the free online version loose wire, the bad part, open faults, vibration, and intermittent electrical problems are simulated. For that version, sight, hearing, and touch are used to troubleshoot. A simple circuit like the one used in the free online industrial electrical problem simulator version, could have 20-30 possible faults.

Electrical Troubleshooting Simulator Compatibility:

Designed to work using, and best used with, the Chrome browser. It will also work with MS Edge and Firefox but with slight visual distortion. This app works on most PC browsers. For part replacement, the game app uses a custom right-click context menu. Additionally, the user can access the context menu by double-clicking or pressing and holding for 3 seconds. Some smartphones do not support the touch-and-hold context menu, so that feature may not work. Tested with the latest high-tech web-enabled TVs/monitors using custom browsers, double-click devices for options may be preferred. We will be working on known compatibility issues and adding updates to the new online industrial electrical troubleshooting certificate course when it becomes available. For those wanting to learn more right away, please consider the download version of the industrial electrical troubleshooting certificate course that you will install on a Windows-based computer. The software installation version is not browser dependent and works on all Windows OS PCs.

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