Basic System Troubleshooting Tips

Ensuring that your industrial control and automation systems continue to operate smoothly and efficiently is critical to your manufacturing operations. Considering the very complex nature and dangerous conditions and hazards these systems operate in, there are some basic troubleshooting steps that the appropriately trained operators and technicians take to identify and communicate problems effectively. Continue reading to learn some simple tips to perform basic checks and learn how to communicate clearly with our experts and representatives, allowing for a quicker diagnosis and resolution.

Safety First

It is critical to always be safe in the complex and hazardous environments these systems operate in. The most important rule is to know your limits! If you are unsure, do not perform any tasks in this article and reach out to your on site technicians or the experts at Embry Automation & Controls. When inspecting any kind of these systems, it is imperative to always follow these safety guidelines:

1. Power Down When Necessary: If a system needs to be inspected closely, ensure it is powered down to avoid electrical hazards.
2. Use Protective Gear: Always wear the appropriate protective gear that your environment requires.
3. Know Your Limits: Recognize when an issue is beyond basic troubleshooting and requires professional intervention.

Common System Issues

It is essential to understand common reasons why control systems might malfunction prior to performing any kind of troubleshooting. We cannot stress enough, if you are not comfortable or if you do not know – then don’t. The trained professionals at Embry Automation & Controls are industry experts and are trained to inspect and perform these tasks safely. 

1. Power Supply Issues: Disruptions in power supply can damage components or cause system failures.
2. Communication Failures: Network and communication system issues can wreak havoc on reliable operations and cause system issues.
3. Sensor and Actuator Problems: Faulty or damaged sensors can cause disruptions or incorrect readings, causing poor overall system performance.
4. Software Errors: Unexpected software and hardware issues can cause glitches in operation and lead to system crashes.
5. Environmental Factors: The elements will wear on components as well – excessive heat, dust or moisture can damage or impact the performance of these systems.

Basic Troubleshooting Steps

1. Perform a Visual Inspection
   • Check for Loose Connections:  Perform a visual check that all cables and connectors are securely plugged in.
   • Inspect for Physical Damage: Observe and check for any signs of wear, damage, or corrosion on equipment.
   • Observe Indicator Lights: Check if there are any warnings or error lights/messages.
2. Verify Power Supply
   • Check Power Sources: Confirm that all power sources are operational and providing the correct voltage. Do not perform these tasks if you are not a trained professional!
   • Examine Backup Power: Confirm that any backup power systems are functioning correctly.
3. Review System Logs and Alerts
   • Check Error Messages: Review any error messages or alerts displayed on the system’s HMI (Human-Machine Interface).
   • Log Review: Access system logs to identify any recent changes or error codes that might indicate the root cause of the problem.
4. Basic Sensor and Actuator Checks
   • Sensor Readings: Compare sensor readings with expected values to identify any discrepancies.

Tips To Communicate With The Experts at Embry Automation & Controls

It is inevitable that some problems absolutely do require the expertise of certified technicians. Professional support from the team at Embry Automation & Controls ensures that issues are addressed correctly and safely, with the intent of preventing any further damage and operational downtime. Our dedicated service team is available 24/7 to assist with diagnosing and resolving issues, either remotely or on-site. When communicating the events that led up to the issues you are experiencing, it is important to have the following:

1. Detailed Description: Provide a detailed description of the issue, including when it started and any changes made prior to its occurrence.
2. Error Codes and Indicators: Share any error codes, indicator lights, and system logs with the technician.
3. Previous Actions: Inform the technician of any troubleshooting steps already taken and their outcomes.

Having a basic understanding of system troubleshooting can greatly improve the process of fixing any issues that arise during the lifecycle of your industrial automation and control systems. It is imperative that all parties involved know their own limits and always keep safety at the highest priority. We hope that this article can provide some insight and guidance on understanding the required troubleshooting basics of these complex systems, and encourage you to contact us in the event your systems are experiencing issues. 

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