Troubleshooting automation systems involves identifying and resolving issues in PLCs, HMIs, sensors, actuators, relays, and communication networks. When done correctly, it minimizes downtime, reduces waste, and ensures operations remain safe and efficient.

Our process begins with understanding the system by reviewing electrical schematics, PLC logic, I/O lists, and network layouts, then comparing normal operation to current symptoms. We identify visible and functional issues such as:

• Machines failing to start
• Stuck cycles
• Defective products

We use HMI alarms, fault logs, status LEDs, and operator feedback to pinpoint trouble areas. Power and signal integrity are verified by checking control voltages, fuses, breakers, and PLC/I/O module indicators, testing as needed with a multimeter. Inputs such as sensors and switches are inspected and confirmed with PLC diagnostics, while outputs like relays, solenoids, and motors are tested—often using PLC force or test modes with caution.

Network communication is assessed by inspecting Ethernet/IP, Modbus TCP, or Profibus links, checking port LEDs, and investigating communication errors or duplicate IP addresses with tools such as:

• Wireshark
• RSLogix
• TIA Portal

We review PLC logic in detail, tracing from HMI inputs or sensors through to final outputs, verifying setpoints, timers, logic conditions, and all safety latches or permissives. Safety circuits are inspected to confirm:

• Safety relays are reset
• Emergency stops are disengaged
• Guards and light curtains are clear

Finally, we test and simulate system operation under safe conditions to confirm that sensors, motors, alarms, and reset functions perform correctly. Each troubleshooting job is fully documented, including the symptoms, root cause, corrective actions, and preventive measures to reduce the risk of recurrence.