The fault that only shows up once a shift

Description and use

TRACE is a free Windows app that records Allen‑Bradley PLC signals, enabling playback and analysis of rare, intermittent faults.

Problem

A fault that appears once per shift or week, disappears before it can be captured on screen, leaving operators and maintenance without evidence.

Outcome

TRACE provides a lightweight, free solution to capture and replay PLC data for intermittent faults, eliminating guesswork and enabling rapid diagnosis.

Workflow

• 1. Install TRACE on a Windows PC.
• 2. Configure TRACE to record desired Allen‑Bradley PLC tags.
• 3. Run TRACE during normal operation until the fault occurs.
• 4. Stop recording and play back the trace to inspect tag values at the fault moment.
• 5. Analyze playback to identify cause of the fault.

Evidence

TRACE is a Windows app that records Allen‑Bradley PLC signals.

Source

It's free. No account. It runs on your PC, and your plant data stays yours.

Source