How to Troubleshoot Your PLC: 10 Pro Tips
Unfortunately, troubleshooting a PLC that won’t communicate effectively with other devices can be challenging, time-consuming, and costly. So where should you start and what steps should you follow?
Key considerations include:
Today’s industrial control systems offer exceptional capabilities to monitor, analyze, control, protect, and improve processes in almost every industry. While process system reliability is usually the biggest improvement sought, many other important benefits exist. Newer automation systems offer:
At PolSys, we specialize in designing, engineering, and building custom industrial control systems for a wide array of industries and applications. We can start with an idea or a complete set of functional specs. Contact us at 713-999-1100 to learn more about how your facility can leverage the latest advancements in control technology.
Unfortunately, troubleshooting a PLC that won’t communicate effectively with other devices can be challenging, time-consuming, and costly. So where should you start and what steps should you follow?
Even "minor" control system issues—like clogged filters, loose connections, etc.—can shut down production. Our Sr. Controls Engineer describes five “easy-to-miss issues” that he often finds.
A major chemical manufacturer operating 24/7 faced frequent shutdowns due to a failing legacy control system on their Regenerative Thermal Oxidizer (RTO). These disruptions led to costly permit violations and production losses. To address these critical issues, we delivered a fast, customized control system upgrade that significantly improved reliability, compliance, and overall operational efficiency.
A global Fortune 100 automotive manufacturer faced major operational challenges due to outdated PLC and HMI hardware in their 4 Regenerative Thermal Oxidizers (RTOs). These legacy systems not only risked future manufacturer support but also contributed to unplanned downtime and inefficiencies. Read how our turnkey control system upgrade delivered robust, reliable performance—minimizing downtime, improving responsiveness, and streamlining operations.