As the year comes to a close, it’s the perfect time for industrial facilities to perform essential maintenance on their automation systems. Proper end-of-year maintenance ensures that your equipment runs efficiently, reduces downtime, and prepares your facility for the challenges of the upcoming year. For the end of year we’ve created a five-step guide to help you effectively manage your industrial automation maintenance.

Read more: End of Year Maintenance

Evaluate System Performance

Start by reviewing the performance of your automation systems over the past year. Analyze key metrics such as production output, energy consumption, and system downtime. Look for patterns in system inefficiencies or recurring issues. Collaborate with operators and technicians to gather feedback on areas needing improvement. This evaluation not only helps pinpoint weaknesses but also provides valuable insights for optimizing operations moving forward.

Inspect and Clean Equipment

Obstructions such as dirt, dust, and debris can accumulate in automation systems. This causes wear and tear and even operational failures. Perform a thorough inspection of all components, including sensors, actuators, conveyors, and control panels. Clean sensitive equipment using appropriate tools and materials to prevent damage. Pay special attention to electrical connections and cooling systems to ensure they remain in good condition and free from obstructions.

Update Software and Firmware

Outdated software and firmware can lead to inefficiencies and vulnerabilities in your automation systems. Check for updates from equipment manufacturers and install them as needed. Updates often include bug fixes, security enhancements, and performance improvements. Ensure that all updates are compatible with your existing hardware and test them in a controlled environment before applying them to critical systems.

Replace Worn Components

Wear and tear is inevitable in industrial automation. Inspect all mechanical and electrical components for signs of degradation, such as frayed wires, corroded connectors, or worn-out belts and gears. Replace these parts proactively to avoid unexpected failures that could lead to costly downtime. Keep an inventory of critical spare parts to facilitate quick replacements when needed.

Plan Future Upgrades

Use this maintenance period to plan for system upgrades or expansions. Evaluate new technologies and trends in industrial automation that could improve your operations. Consider implementing predictive maintenance tools or integrating IoT solutions for better system monitoring and control. Budgeting for these upgrades now can help ensure a seamless transition in the future.

Conclusion

By taking the time to conduct thorough end-of-year maintenance on your industrial automation systems, you set the stage for a more productive and trouble-free year ahead. Regular maintenance not only extends the lifespan of your equipment but also enhances overall operational efficiency, saving your facility time and money in the long run.

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In Need of Parts?

If you find yourself needing a new motor or servo amplifier after completing your year end maintenance reach out to us! Our team of experts can make sure you have the right equipment needed to make sure your 2025 starts off without a hitch!

Allen-Bradley Programmable Logic Controllers (or PLC) remain widely used in industrial automation. Programming their PLCs opens a multitude of opportunities for those willing to learn how to do so. Learning to program them requires understanding both the hardware and the programming software, typically Rockwell Automation’s RSLogix 500 or Studio 5000 (for ControlLogix or CompactLogix PLCs).

Read more: Beginner’s Guide to Programming an Allen-Bradley PLC

Understanding the PLC

The first step to programming a PLC is understanding what the heck a PLC even is. This article gives a more in-depth explanation into understanding PLC’s. The basic rundown is that a PLC is basically a computer used to control machines and processes. It accomplishes this using inputs like sensors, and outputs such as actuators. While these systems use a variety of components there are definitely fundamental ones that are universally found across multiple systems. The components are crucial to system operation.

PLC System Components

1. Processor/CPU: Executes the program logic.
2. I/O Modules: Interface for sensors and actuators.
3. Power Supply: Powers the PLC.
4. Communication Port: Connects to programming devices or networks.

Installing the Required Software

1. Get the Software:
   • For MicroLogix series, use RSLogix 500.
   • For CompactLogix/ControlLogix, use Studio 5000 Logix Designer.
2. Install RSLinx:
   RSLinx is the communication software needed to connect your PC to the PLC.
3. Licensing: Make sure you have a valid software license. If you need the software package for a one off job, Allen-Bradly offers free trial versions for many of their software packages.
   

Connecting the PLC

1. Hardware Setup:
   • Connect your PC to the PLC using USB, Ethernet, or Serial (depending on the model).
   • Ensure proper power is supplied to the PLC.
2. Communication Setup in RSLinx:
   • Open RSLinx and configure a communication driver (e.g., Ethernet/IP, RS232).
   • Test communication to ensure the PC recognizes the PLC.

Create a New Project

1. Open the Programming Software:
   • In RSLogix 500 or Studio 5000, create a new project.
2. Select Model:
   • Choose the correct processor type (e.g., MicroLogix 1400, CompactLogix L33ER).
3. Configure I/O:
   • Define the input and output modules in the program, ensuring they match the physical hardware.

Learn Ladder Logic

1. What is Ladder Logic?
   Ladder Logic is the primary programming language for PLCs. It mimics electrical relay logic with “rungs.”
2. Basic Elements of Ladder Logic:
   • Inputs: Represented by normally open (NO) or normally closed (NC) contacts.
   • Outputs: Represented by coils or actuators.
   • Timers/Counters: For delay or counting applications.
   • Branching: For parallel operations.

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Write an Easy Program

Once you go over the basics of PLC programming, take a crack and writing your own program! One example of a simple programming project is creating a function that toggles a motor START and STOP.

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Conclusion

Understanding how to program Allen-Bradley PLCs seems intimidating. However, the opportunities and advancements that come with learning how to program PLCs makes the struggle worth it.

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Having PLC Issues?

Our team of qualified experts are ready to assist you with your PLC needs. Reach out today either by phone: (800) 691-8511 or email: sales@mroelectric.com.

Arc flash incidents are among the most dangerous hazards in the electrical industry, posing serious risks to personnel and equipment. Properly labeled equipment can help prevent injuries and fatalities associated with arc flash incidents. For this reason, the National Fire Protection Association (NFPA) and the National Electrical Code (NEC) have established rigorous guidelines for arc flash labeling. This article explores the legal and safety requirements for arc flash labels, with a focus on NFPA 70E and NEC standards, while discussing the critical role these labels play in workplace safety and regulatory compliance.

Read more: Legal and Safety Requirements Regarding Arc Flashes

What is an Arc Flash?

As we discussed in a previous post, an arc flash occurs when an electric current leaves its intended path, traveling through the air from one conductor to another, or to the ground. This incident can result in temperatures of up to 35,000°F, releasing intense heat, light, sound, and pressure that can cause severe burns, hearing loss, and even death. Recognizing and controlling arc flash hazards is essential for worker safety, and labels play a crucial role in alerting workers to the potential dangers of working with energized equipment.

Legal and Regulatory Requirements for Labels

NFPA 70E: Standard for Electrical Safety in the Workplace

The NFPA 70E is a key standard that provides guidelines for electrical safety in the workplace. It outlines safety practices and requirements for identifying arc flash hazards. It determines appropriate personal protective equipment (PPE), and providing training for workers who may be exposed to electrical hazards.

Under NFPA 70E, labels must include specific information to inform workers about the potential hazards associated with electrical equipment. These requirements include:

• Nominal System Voltage: Identifies the voltage level of the equipment, allowing workers to determine the level of PPE and other safety precautions needed.
• Arc Flash Boundary: Defines the minimum safe working distance from the equipment that requires protection.
• Incident Energy Level or PPE Category: Indicates the level of energy (calculated in calories per square centimeter) potentially released in an arc flash, along with the corresponding PPE level required to protect workers.

It is imperative to place these labels on electrical panels, switchboards, motor control centers, and other equipment where arc flash risks exist. Compliance with NFPA 70E standards not only enhances worker safety but also reduces liability and helps companies avoid potential regulatory penalties.

NEC: National Electrical Code

The National Electrical Code (NEC), also known as NFPA 70, provides guidelines for electrical installations to promote safe electrical practices. Article 110.16 of the NEC addresses labeling requirements, stipulating that electrical equipment likely to require examination, adjustment, servicing, or maintenance while energized must be marked to warn qualified personnel of potential hazards.

The NEC requires that arc flash labels contain a warning message indicating the presence of an arc flash hazard. However, it does not mandate specific details like incident energy levels or PPE requirements. The intent of NEC labeling requirements is to ensure that anyone working on or near the equipment is aware of potential hazards, while NFPA 70E provides the detailed information necessary for personnel safety.

Why Proper Arc Flash Labeling Is Essential

Proper arc flash labeling is crucial for multiple reasons, including the protection of workers, ensuring compliance with regulations, and reducing liability for organizations. Here are the primary reasons why proper arc flash labeling is essential:

1. Enhances Worker Safety: Accurate and comprehensive arc flash labels help workers identify hazards and determine the appropriate safety measures, PPE, and distance requirements. In the event of an arc flash, properly labeled equipment can prevent or significantly reduce injuries by guiding workers on how to protect themselves.
2. Facilitates Compliance with Regulatory Standards: Compliance with NFPA 70E and NEC is mandatory for organizations. Failing to adhere to these standards can result in legal consequences, regulatory fines, and increased scrutiny from safety inspectors. By meeting labeling requirements, companies can demonstrate a commitment to workplace safety and regulatory compliance.
3. Improves Risk Management and Liability Protection: In the event of an arc flash incident, proper labeling can serve as evidence that an organization took reasonable steps to protect its employees. Failure to label equipment correctly increases liability in the event of an incident. Proper labeling helps mitigate this risk and shows due diligence in maintaining a safe workplace.
4. Supports Effective Training and Awareness: Arc flash labels also play an educational role, providing visual reinforcement of electrical safety practices. When combined with formal training, these labels reinforce key safety information, helping workers remember and follow established protocols.
5. Promotes Maintenance Best Practices: Arc flash labels indicate when equipment needs de-energizing or when a specific operation requires specific protective measures. This information not only protects workers but also supports maintenance planning. It also ensures that operators follow proper procedures to reduce equipment downtime and improve operational efficiency.

Arc Flash Labeling Best Practices

When implementing arc flash labels, consider the following best practices to ensure compliance and maximize effectiveness:

• Regularly Update Labels: Labels should be reviewed and updated whenever there is a change in the electrical system, such as equipment upgrades or modifications that could alter the hazard level.
• Use Durable Materials: Labels should be made from materials that can withstand harsh conditions, including high temperatures, moisture, and chemical exposure, to ensure they remain legible and effective over time.
• Maintain Consistency in Label Design: Consistent labeling formats and terminology across equipment help workers quickly identify and understand hazards. Clear symbols and standardized language make labels more accessible and effective.
• Incorporate Labels into Training Programs: Safety training should include information on reading and understanding arc flash labels, as well as practical demonstrations to reinforce key safety practices.

Conclusion

Proper arc flash labeling, as mandated by NFPA 70E and NEC, is vital for workplace safety and regulatory compliance. These labels are not merely informational—they are crucial safety tools that guide workers on protective measures and ensure that hazards are clearly communicated. By following established standards and best practices, companies can protect their workers, fulfill their legal obligations, and create a safer work environment.

An arc flash stand as one of the most dangerous electrical hazards encountered in industrial settings. They occur when an electrical current travels through the air between two conductive points, creating an intense burst of heat and light. This sudden, high-temperature discharge of energy can cause severe injury, damage equipment, and even lead to fatalities. While seemingly a rare event, arc flashes occur more than many realize. The consequences if we ignore proper precautions end up being catastrophic.

The energy released during an arc flash can reach temperatures as high as 35,000°F, which is four times the surface temperature of the sun. This extreme heat can vaporize metals like copper and steel, causing molten metal particles to fly through the air. The accompanying pressure wave from the rapid expansion of air can also result in physical injuries, such as hearing damage, lung damage, and blunt-force trauma from projectiles. Additionally, the bright light produced can lead to temporary or permanent blindness. The sheer intensity of them is why it is so critical to understand the risks involved.

Read more: Understanding an Arc Flash

What Causes an Arc Flash?

Several factors can cause an arc flash. These include equipment failure, improper installation, faulty maintenance, or human error. For instance, using improperly rated or damaged tools, dropping metal objects near live equipment, or working on energized systems without proper safety gear can all result in an arc flash. Even something as simple as dust or corrosion on electrical equipment can lower insulation resistance, allowing an arc to form. The likelihood of these events increases significantly in high-voltage environments. Electrical substations or industrial plants that store and manage large amounts of energy daily, often see the highest risk.

The Dangers of an Arc Flash

An arc flash can lead to significant damage to equipment, causing costly downtime and repairs. High-energy ones can destroy electrical panels, cables, and machinery, resulting in production delays and expensive replacements. Worse, if an arc flash ignites nearby flammable materials, it could trigger secondary fires, further escalating the damage. Therefore, many companies invest in preventative measures like sophisticated detection systems and remote operation technology, which allow workers to interact with electrical equipment from a safe distance.

How to Protect Your Equipment

Preventing arc flash incidents starts with the proper training and education of personnel working in environments with electrical systems. Workers need thorough training on how to understand the hazards of arc flashes. The should also know how to identify risks, and the correct safety procedures to follow. One of the most effective preventive measures is to always de-energize electrical equipment before performing any maintenance or repairs. Lockout/tagout (LOTO) procedures, which involve isolating the energy source and placing a lock on the equipment to prevent accidental re-energization, are crucial to minimizing the risk of ocurrences.

Another key precaution is the use of appropriate personal protective equipment (PPE). Workers exposed to potential arc flash hazards should wear flame-resistant (FR) clothing, gloves, and face shields that meet the arc rating required for the specific electrical task. This gear can withstand the high temperatures and energy released during an arc flash which significantly reduces the severity of injuries. Additionally, using safety tools, such as insulated hand tools, reduces the likelihood of accidental contact with live components. It’s also important to maintain a safe working distance from energized equipment, especially in high-voltage environments.

Lastly, routine inspection and maintenance of electrical systems are vital in preventing arc flash incidents. Equipment should be regularly checked for signs of wear, damage, or corrosion, which could compromise insulation and increase the risk of an arc flash. Faulty components should be repaired or replaced promptly. Implementing arc-flash detection and mitigation systems can further reduce risks by automatically shutting down electrical systems if dangerous conditions are detected. By combining proper safety practices, equipment maintenance, and protective measures, companies can significantly lower the chance of arc flash events and protect both workers and equipment.

Conclusion

In conclusion, an arc flash is a potentially deadly hazard that demands respect and proper safety measures. Through a combination of education, awareness, and adherence to established safety protocols, the risks of incidents can be minimized. Understanding the causes, consequences, and prevention strategies not only ensures the safety of workers but also helps maintain operational efficiency and reduce the financial impact of equipment failure. Whether you’re an electrician, engineer, or plant manager, prioritizing arc flash safety is a non-negotiable part of protecting both people and infrastructure.

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Damaged Part? Need a Replacement?

If you’re experiencing a damaged drive from an arc flash reach out to us! Our team of experts are ready to help you get your operation back up and running in no time. Our customer service team can be reached by email: sales@mroelectric.com or by phone: (800) 691-8511.

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If you liked this article, you may enjoy our other article covering “dirty power” and its effects on industrial equipment.

In today’s tech-driven world, many of our most valuable devices rely on a clean and stable power supply. But what happens when the power running through your home is less than ideal? This is where “dirty power” comes into play. Dirty power refers to any irregularities or distortions in your electrical supply that can cause serious issues for electronics and appliance.

Read more: The Effects of Dirty Power on Electronics

What is Dirty Power?

Dirty power occurs when electricity deviates from the smooth, stable sine wave it’s supposed to follow. Ideally, your power supply maintains a consistent voltage and frequency, providing energy that flows smoothly to all your devices. However, dirty power can manifest through several types of disturbances, including:

• Voltage spikes – Sudden increases in voltage.
• Voltage sags – Short drops in voltage.
• Harmonic distortion – Alterations in the waveform of electricity.
• Electrical noise – High-frequency interference from other sources.
• Power surges – Brief bursts of excess power.

These irregularities can be caused by several factors, such as faulty wiring, poor grounding, nearby heavy machinery, and even power grid fluctuations. Appliances like solar inverters or other power-generating equipment can also introduce distortions into your electrical system.

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Dirty Power’s Impact on Industrial Automation

Dirty power can have particularly severe consequences for industrial equipment, as these systems often rely on precise electrical inputs to operate efficiently. Voltage sags or spikes can cause motors to overheat, leading to premature wear and tear on critical components. This not only shortens the lifespan of expensive machinery but can also result in unexpected downtime for repairs, disrupting production schedules. Additionally, sensitive industrial equipment like programmable logic controllers (PLCs) and automated systems may malfunction or produce faulty outputs when exposed to harmonic distortion or electrical noise, increasing the risk of operational errors and product defects.

The financial impact of dirty power on industrial operations can be significant. Frequent power irregularities can lead to higher energy consumption as machines work harder to compensate for unstable electrical inputs, driving up utility costs. Furthermore, unplanned equipment failures can incur expensive repair and replacement costs. In industries where precision is paramount—such as manufacturing, pharmaceuticals, or data centers—dirty power can cause costly errors, affecting product quality and regulatory compliance. Protecting industrial equipment with solutions like power line conditioners, voltage regulators, and uninterruptible power supplies (UPS) is essential to ensuring both the reliability and efficiency of operations.

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Alternatively, you can find out more about extending the life of your servo motor here.