Resources for the people who keep plants running
Calculators, field guides and reference material for maintenance and engineering teams. Use them to identify a part, size a replacement or plan spares, then send us the details.
- 9
- free tools
- 18
- in-depth guides
- 66
- glossary terms
- 2
- templates and checklists
Free tools
Quick answers for sizing, scaling and identifying. Every tool ends with a way to send us the details.
Motor current calculator
Estimate full-load amps from kW, voltage, efficiency and power factor.
Open the toolkW to HP converter
Convert kW, mechanical hp and metric hp, and find the nearest standard motor size.
Open the tool4–20 mA scaling calculator
Convert a loop current to engineering units and PLC counts, and back again.
Open the toolDowntime and critical-spares calculator
Compare the cost of waiting for a part with the cost of holding one.
Open the toolIP rating decoder
Decode IP54, IP65, IP66 and more into plain language.
Open the toolPart number identifier
Paste an order number and see which brand and product family it belongs to.
Open the toolMotor speed and poles calculator
Work out poles from nameplate rpm, or synchronous speed from poles and frequency.
Open the tool24 V DC power supply sizing
Add up panel loads, add headroom and get the next standard supply size.
Open the toolObsolescence risk check
Answer six questions to see how exposed a part or machine is, and what to do about it.
Open the tool
Guides
Practical, vendor-neutral advice on identifying, selecting, fault finding and planning.
Identify parts
- 2 min readHow to read a PLC module label before you ask for a quoteThe few details on a PLC or I/O module label that decide whether a replacement will fit. What to photograph and what to write down.
- 2 min readSiemens order numbers explained: how to read a 6ES7 part numberWhat the blocks in a Siemens order number mean, how to tell an S7-300 from an S7-1500 from the first digits, and why the last block matters.
- 2 min readMotor nameplate explained: every field and what it means for a replacementRead a three-phase motor nameplate: kW, volts, amps, rpm, frame, IE class, IP rating and mounting. What to send when ordering a replacement or a drive.
Fault finding
- 2 min readWhy VFDs trip: common causes and what to check firstOvercurrent, overvoltage, undervoltage, overtemperature and earth-fault trips explained, with a practical first-pass check for each.
- 2 min readPLC will not go to RUN: a structured first-pass checklistA step-by-step way to diagnose a PLC stuck in STOP or showing a fault light: power, mode, LEDs, diagnostic buffer, memory, hardware changes and communications.
- 2 min read4–20 mA loops explained: how they work and how to fault-find themWhy 4–20 mA is the industrial standard, how two-wire and four-wire transmitters differ, what the fault bands mean and how to find a bad loop.
Selecting equipment
- 2 min readSoft starter or VFD? How to choose for a motorWhat a soft starter does, what a variable frequency drive does, and a simple way to choose between them for pumps, fans, conveyors and crushers.
- 2 min readChoosing an industrial sensor: inductive, capacitive or photoelectricHow to match a sensor to what it must detect, and the details that decide whether a replacement fits: sensing distance, mounting, output type and connector.
- 2 min readRepair, replace or retrofit: what to do when a drive or PLC failsA practical way to choose between repairing a failed drive or PLC module, replacing it like for like, or using the failure as the moment to upgrade.
- 3 min readChoosing a replacement VFD: eight things to check before you orderHow to select a replacement variable frequency drive: motor data, duty rating, supply, control interface, altitude derating, braking and parameter migration.
- 2 min read24 V DC power supplies in control panels: sizing, headroom and warning signsHow to size a 24 V DC supply, why headroom matters, what ageing looks like, and how a weak supply causes random PLC stops.
Planning and risk
- 2 min readA part is discontinued: five routes to keep the machine runningThe five options when a PLC, drive or HMI is no longer sold new, what each is good for, and what to check before you commit.
- 2 min readNew, new old stock, surplus, refurbished or used: what the terms meanPlain definitions of the condition terms used for automation parts, and what to ask for in writing before you buy.
- 2 min readControl panel preventive maintenance: a practical checklistA schedule of checks that catch heat, dust, loose connections and ageing power supplies before they stop production, with a frequency for each.
- 3 min readCritical spares for a production line: what to keep on the shelfHow to decide which automation spares are worth holding in stock, using downtime cost, lead time and failure history instead of guesswork.
- 2 min readLoad shedding and your control system: protecting PLCs, drives and panelsWhy damage happens when power returns, and what surge protection, voltage monitoring, UPS, drive settings and PLC retention can do about it.
- 2 min readObsolescence planning for automation: lifecycle stages and what to do at eachHow manufacturers phase out PLCs and drives, how to audit your installed base, when to buy last-time spares and when to migrate.
- 2 min readGenuine, grey-market and counterfeit automation parts: how to protect your plantWhy fake and unauthorised parts reach plants, the warning signs, and the questions to ask any supplier before you buy a PLC, drive or sensor.
Reference
- Automation glossary66 terms in plain language, from 4–20 mA to VFD.
- Part number prefix referenceSiemens, Allen-Bradley, Delta and Schneider prefixes and what they mean.
- Nameplate photo checklistWhat to photograph and write down. Printable.
- Spares by seriesS7-300, ControlLogix, PowerFlex, Altivar and more, with what we source for each.
Downloads
Critical spares register template
A spreadsheet-ready register with columns for order number, version, stock level, lead time, downtime cost and lifecycle status. Opens in Excel or Google Sheets.
Download CSV
Found the part? Ask for the price.
Send the part number or a nameplate photo. An engineer replies with availability, lead time and price.
Get a quote
Tell us what you need. An engineer replies with availability, lead time and price.
1/2