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DCS系统在工业生产过程的广泛应用，使可靠性、稳定性问题更加突出，也使人们对整个系统要求越来越高。人们希望DCS系统尽量少出故障，又希望DCS系统一旦出现故障，能尽快诊断出故障部位，并尽快修复，使系统重新工作。下面简单介绍故障大体分类及故障诊断的一般方法。
　　一、DCS系统故障的分类
　　为了便于分析、诊断DCS系统故障发生的部位和产生原因，可以把故障大致分为如下几类。
　　1、现场仪表设备故障
　　现场仪表设备包括与生产过程直接联系的各种变送器、各种开关、执行机构、负载等。现场仪表设备发生故障，直接影响DCS系统的控制功能。在目前的DCS控制系统中，这类故障占绝大部分。这类故障一般是由于仪表设备本身的质量和寿命所致。
　　2、系统故障
　　这是影响系统运行的全局性故障。系统故障可分为固定性故障和偶然性故障。这类故障一般比较明显且影响也是局部的，它们主要是由使用不当或使用时间较长，模板内元件老化所致。
　　3、硬件故障
　　这类故障主要指DCS系统中的模板(特别是I/O模板)损坏造成的故障。这类故障一般比较明显且影响也是局部的，它们主要是由使用不当或使用时间较长，模板内元件老化所致。
　　4、软件故障
　　这类故障是软件本身所包含的错误所引起的，软件故障又可分为系统软件故障和应用软件故障。系统软件是DCS系统带来的，若设计考虑不周，在执行中一旦条件满足就会引发故障，造成停机或死机等现象。此类故障并不常见。应用软件是用户自己编定的。在实际工程应用中，由于应用软件工作复杂，工作量大，因此软件错误几乎难以避免，这就要求在DCS系统调试及试运行中十分认真，及时发现并解决。
　　5、操作、使用不当造成故障
　　在实际运行操作中，有时会出现DCS系统某功能不能使用或某控制不封不能正常工作，但实际上DCS系统并没有毛病，而是操作人员操作不熟练或操作错误所引起的。这对于初次使用DCS系统的操作工较为常见。

ALLEN BRADLEY 150-B35NBDA-J1 NSFP 150B35NBDAJ1

GENERAL ELECTRIC DS3800HSCD1G USPP DS3800HSCD1G

SQUARE D 8538SFA23-V02S USPP 8538SFA23V02S

RELIANCE ELECTRIC 0-60002-5 USPP 0600025

ASEA BROWN BOVERI SMPS-7738-E USPP SMPS7738E

Siemens 6ES5 390-0UA11 6ES53900UA11

Siemens 6ES5-240-1AA11 USPP 6ES52401AA11

SIEMENS 6ES5 375-0LD31 MEMORY MODULE

SIEMENS BOARD 6ES5-400-0AA11 6ES5 400 0AA11 6ES54000AA11 SPCB467 SIEMEN

Siemens 6ES5 980-0AE11 NSFP 6ES59800AE11

Siemens 6ES5318-8MB12 6ES53188MB12

Siemens Modem 6ES7241-1AA22-0XA0

Reliance Electric 57405-E 0- 57405E Analog I/O Drive Module

Texas Instruments 500-5018

Spirent Adtech AX/4000 Utopia Interface pn 400323

Value upgrade kit w/Onboard Videoaudio|550W|Elite Case

SIEMENS C98043-A7001-L2 6RA70 CUD1 CONTROL BOARD

Modicon AS-W617-012

Schneider Modicon AS-WBXT-201 BUS EXTENSION CABLE FS

Schneider Modicon AS-B827-032 24VDC INPUT MODULE

Schneider Modicon AS-BDAP-216 NSPP ASBDAP216

Schneider Modicon AS-B875-102

Schneider Modicon TSX Compact DEP216/AS-BDEP-216

Schneider Modicon B805 AS-B805-016 INPUT MODULE 115 V AC

Schneider Modicon Premium TSXAEY414 TSX 4 ANA I. Multirange

SCHNEIDER/MODICON PREMIUM16 CH DIGITAL INPUT MODULE 24VDC/ACTSXDEY16A2

RELEASE SuperMicro X9DR3-LN4F MB FULL MFR

Siemens 6ES5-470-7LB13 Analog Output Module

SIEMENS SINUMERIK S7-300 6FX1124-6AD02 6FX11246AD02 NIB

MITSUBISHI QX524 SIO COMMUNICATION MODULE

SIEMENS Simodrive 611 LT 160A 6SN1124-1AA00-0EA1

SIEMENS Sinumerik Module Modul 6FC5111-0CA03-0AA2

SIEMENS CARLING SWITCH 6FC54-73 NSPP 6FC5473

ALLENBRADLEY1756-OA8FACTORYSEALEDCONTROLLOGIXOUTPUTMODULE.

Allen Bradley SLC 500 Output Module 1746-OB32 Ser C White Label

ABB robot power supply 3HAB8101-16/11C DSQC358G

A06B-0142-B084#0076 FANUC SERVO MOTORS REMANUFACTURED

0010-03338 ASSY HEATER 8" SR OSCR WXZ

MODICON MM-PMA2-20S NSFP MMPMA220S

ALLEN BRADLEY 150-A360NBD USPP 150A360NBD

ADEPT TECH 90400-20045/XY-HRS-045M201 USPP 9040020045XYHRS0

GE FANUC TGT-AI0V-16-0-AC USPP TGTAI0V160AC

SQUARE D 7S1FIS NSFP 7S1FIS

SIEMENS 6FM1723-3CA00 USPP 6FM17233CA00

ALLEN BRADLEY 810-NX46 USPP 810NX46

Siemens 6ES5 942-7UA11 6ES59427UA11

Siemens SIMATIC S5 095U CPU 6ES5095-8MA05 BNIBOVPFACTORY SEALED

SIEMENS 6ES5-525-3UA11/6ES5525-3UA11 INTERFACE XLNT

Siemens 6ES5 451-4UA12 I/O Module

Siemens 3RG7642-3BG00 Proximity Sensor Switch Opto-Bero

Siemens ET200M 153-1AA03-0AB0

Scalable package: Ask about adding more SB168-ES units

Square D 9080 K-1

Siemens ASI Interface Module 3RK2200-0CE02-0AA2

WE SHIP SAME CISCO AIR-LAP1261N-A-K911GN CTLR-BASED AP EXT ANT A REG DOMA

Siemens 6SE6420-2UD23-0BA1 6SE64202UD230BA1

Siemens TP27-6 6AV3627-1NK00-2AX0 Touchscreen Glass

Schneider Modicon Remote I/O Processor AS-P890-000 ASP890000

Schneider Modicon ASBCTR205 High Speed Counter Module AS-BCTR-205

Schneider Modicon AS-B827-032 ASB827032 Fast Shipping

Schneider Modicon AS-B865-001

Schneider Modicon ASW808002 AS-808-002

Schneider Modicon AS-C924-000 24-Bit CPU Module AS-IS

Schneider PLC Output Module TSXDSY16R5 NIB

SIEMENS 6ES5464-8ME11 AMALOG INPUT MODULE

RSP-16 CISCO 7500 ROUTE SWITCH PROCESSOR 16 SPARE

SIEMENS COROS OP25 OPERATOR PANEL 6AV3525-1EA01-OAXO -

SIEMENS SINUMERIK 840C/840CE 6FC5111-0CA73-0AA1 6FC51110CA730AA1 NIB

Rivulet Communications NCU-51 RTM Transition Module

SIEMENS 6SN2-132-5KW11-1BA1 USPP 6SN21325KW111BA1

SIEMENS 6RB2060-0FB00 6RB2060-OFB00 6RB2O6O-OFBOO 6RB2 060-0FB00 SIMODRIVE Board

SIEMENS 6FC5110-0DB03-0AA4 NSFP 6FC51100DB030AA4

AllenBradley2711-T6C9L1/A2711T6C9L1

Allen Bradley VersaView 1700P Interface Panel Catalog 6181P-17NPXPH

ABB EH700C-111 CONTACTOR IN A

Advance Lifts Lift & Tilt Table PT-35364 48" X 48" Table Capacity 3500 PT35364

(J1) 1 Huge Indramat Servo Motor MAC090B-2-JD-4-C/100-A-1/WI520LX J1

KREUTER MFG KMD-5831 USPP KMD5831

ADEPT TECH PA-4 USPP PA4

FOXBORO P0926CP USPP P0926CP

FANUC A06B-0502-B031/0008 USPP A06B0502B031000

SICK OPTIC ELECTRONIC CLV-490-6010 USPP CLV4906010

RELIANCE ELECTRIC 0-51865-2 NSFP 0518652

SAFTRONICS GP10E1ST34025B1 USPP GP10E1ST34025B1

Siemens 6ES5 464-8MA11 6ES54648MA11

Siemens 6ES5-931-8MD11 FACTORY SEALED

SIEMENS 6ES5-431-4UA12 USPP 6ES54314UA12

Siemens 6ES5 526-3LA21 EXPANSION UNIT EXTENSION CARD BOARD C79040-A32-C751 54513

Siemens S5 6ES5 512-5BC21 Interface Module.

Siemens Board C98043-A7014-L1

Siemens 6ES7 131-1BL01-0XB0 -FS- 6ES71311BL010XB0

Square D 8010 AXS-211

Nortel NT7E02PA OC12/STM4 Intra-Office Interface Module

WS-C6509-E SUP720-3BXL X6724-SFP X6748 6509

Siemens 6ES7214-2AD23-0XB0

Siemens Simatic 6ES5 095-8MB01 6ES5095-8MB01

Reliance 57C330

Schneider Modicon Gould AS-E685-904 Memory Module Executive Cartridge

Schneider Modicon AS-B356-001 USPP ASB356001

Schneider Modicon AS-S911-000 USPP ASS911000

Schneider Modicon AS-B908-110

Schneider Modicon AS-B807-132 Input Module

MODICON AS-B840-008 OUTPUT MODULE REED REED RELAY

SIEMENS INPUT MODULE CATTI305-05N NIB

Siemens 6ES5 430-4UA14 -FS- 6ES54304UA14

Siemens Panel 6AV3515-1MA20-1AA0 6AV35151MA201AA0

SIEMENS SE47.1 6DD1681-0EH1 OPTICAL COUPLER MODULE

TOYODA TOYOPUC THU-5563 DLNK-S2 COMMUNICATION MODULE

SIEMENS 6SN1118-0DH12-0AA0 6SN11180DH12-0AA0

SIEMENS SIMODRIVE 611 6SN 1123-1AA00-0CA0 MORE AVAILABL

SIEMENS 6FC5410-0AY01-0AA0 Free Ship

Advantech PCL-745B RS-422/485 Card PCL-745B REV.B1

Allen-Bradley 1756-OF8 8 Point Analog Output Module 1756-OF8/A

ABB BAILEY IMMFP12 SYMPHONY MULTI-FUNCTION PROCESSOR MODULE 5V 10W REV A 84832

ADEPT SIX300

6SN1123-1AA00-0DA1 SIEMENS DRIVES REMANUFACTURED

HONEYWELL 51401288-100 USPP 51401288100

TAYLOR ELECTRONICS 6204BZ10100D USPP 6204BZ10100D

CUTLER HAMMER W201KGCF USPP W201KGCF

CONTROL TECHNIQUES DXE-4120CB USPP DXE4120CB

OMRON F160-C15E-2 NSFP F160C15E2

MODICON 5136-MOD-ISA-V4 NSFP 5136MODISAV4

GENERAL ELECTRIC DS3800NEPB1C1B USPP DS3800NEPB1C1B

Siemens 6ES5 304-3UA12 6ES53043UA12

Siemens 6ES5-512-5BC21 NSFP 6ES55125BC21

SIEMENS 6ES5-315-8MA11/6ES5315-8MA11 INTERFACE MODULE NIB

Siemens 6ES5 095-8MA03 CPU SISMATIC WORKING TESTED

Siemens 6ES5 Bus Module 700-8MA11

Siemens 6GK1503-2CB00 in Box

Siemens TP177A 6AV6642-0AA11-0AX1 Touch Glass + Film

Siemens 6ES5525-3UA21

Kingspec Flash DOM Disk On Module 16GB 40Pin Vertical IDE PATA Interface MLC

YASKAWA ELECTRIC JAMSC-C8120 NSPP JAMSCC8120

Siemens 6ES7 216-2AD23-0XB0 6ES7216-2AD23-0XB0 in Box, Seal Intact, FreeShip

SIEMENS OP270 6AV6 542-0CA10-0AX0 6AV6542-0CA10-0AX0

Red Lion AS-B253E

Schneider Modicon AS-B827-032 Input Module -

Schneider Modicon AS-5B47J02A NSFP AS5B47J02A

Schneider Modicon AS-M909-022 USPP ASM909022

Schneider Modicon AS-B132-000 USPP ASB132000

Schneider Modicon Analog Output Module DAU202 AS-BDAU-202

MODICONASBDAU208OUTPUTMODULEDAU208

Siemens Simatic U-25N U25N Input Module 100-120 VAC Automation Direct PLC

Telemecanique MODICON TSX Micro TSX3710001

Siemens Simatic S5 Output Module 24VDC 6ES5 454-7LB11

SIEMENS 11-D-4506-01 NSFP 11D450601

SIEMENS Sinumerik CPU 6FC5110-0BB01-0AA1 E Stand A

SIEMENS 6SN1111-0AB00-0AA0 SIMODRIVE 611 SURGE ARRESTER

SIEMENS Simodrive 6SN1130-1AA11-0CA0 6SN11301AA110CA0

SIEMENS OP012 6FC5203-0AF02-0AA0 Membrane Keypad 6FC5 203-0AF02-0AA0

Advantech PCL-745 Rev.a2 Isolated RS-422/485

ALLEN-BRADLEY 2711-M3A18L1 PanelView 300 Micro ! WOW !

ABB 57275871 / UC86-8CH / UC868CH / UC86 8CH / UC86.8CH

ACME ELECTRIC TP793694S Transformer, 480Y/277V, 45kVA G2

AALLEN BRADLEY 1336 AC Drive 1336-B030-EOF-L1 30HP

8500-B1D-L1B ALLEN BRADLEY SERVO MOTORS REMANUFACTURED

SIEMENS 6FM1-726-3CA00 USPP 6FM17263CA00

ASEA BROWN BOVERI INNPM-22 NSFP INNPM22

ASEA BROWN BOVERI 3HAB2242-1 USPP 3HAB22421

MITSUBISHI FR-SE-S-22K-BN401U USPP FRSES22KBN401U

INDRAMAT HDS03.2-W075N-HS45-0 USPP HDS032W075NHS450

ALLEN BRADLEY 7300-UCT-3 USPP 7300UCT3

STI MS4348B-X USPP MS4348BX

Siemens 6ES5-430-7LA12 NSFP 6ES54307LA12

SIEMENS 6ES5 464-8ME11 -FS- 6ES54648ME11

SIEMENS 6ES5457-5AB11 6ES5 457-5AB11 XLNT

Siemens S5 6ES5 312-3AB11 6ES5312 6ES53123AB11

Siemens 6ES7 407-0KA02-0AA0 6ES7407-0KA02-0AA0 in Sealed Box

Siemens RA81 SERVO CONTROL Board 6416261

PROSOFT MVI46-MCM MVI46MCM

HILSCHER CIF-50-PB COMMUNICATION MODULE INTERFACE CIF50PB

Veeder Root Vapor Sensor Interface Module

Siemens 6AV6642-0DA01-1AX1 OP177B No Box

Siemens LOGO 6ED1 055-1CB00-0BA0 in sealed box

Omron 3G2A5-BC081

Schneider Modicon AS-S908-110 ASS908110 Processor

Schneider Modicon AS-B883-200 INPUT MODULE LINEAR MV 10POINT

Schneider Modicon AS-E908-131 REMAN ASE908131

Schneider Modicon GOULD OUTPUT MODULE AS-B804-016 REMAN ASB804016

Schneider Modicon AS-BADU-205 INPUT MODULE ASBADU205

Schneider Modicon POWER SUPPLY MODEL AS-P800-003

Telemecanique ABA 6PT311 Temperature Module

Schneider Telemecanique ATV31HV30N4A NIB

Siemens6FX1122-8BD046FX11228BD04SINUMERIK805SMDigitalOutputModule

SIEMENS 6AV6-545-0AH10-0AX0/6AV6545-0AH10-0AX0 TOUCHSCREEN INTERFACE XLNT

SIEMENS Sinumerik 3T Panel 6FX11268AA00 _ 6FX1126 8AA00

GE Fanuc IC610CCM105D Data Communication Module Series

SIEMENS SIMODRIVE 6SN1145-1BA01-0BA1SINUMETIK 840D 6FC5247-0AA00-0AA26SN1123

SIEMENS SINUMERIK 6FC5 203-0AF02-0AA0 Membrane Keypad

SIEMENS Moore Pneumatic Pressure Transmitter 174N 0-5 H2O

ALLEN-BRADLEY LOT! CAT 1201-HAZ 2 PROGRAMMING TER.

AB Allen Bradley 1606-XL480E-3W Power Supply 460/480V 24VDC, 20A

AC INVERTER DRIVE vfd X4C4050-0C 50hp 40hp 380v 400v -460v volt

A06B-0502-B072#7008 FANUC SERVO MOTORS REMANUFACTURED

75 HP Rotary Phase Converter with Starter

RELIANCE ELECTRIC 84586-24R USPP 8458624R

ALLEN BRADLEY 4100-214-PRL USPP 4100214PRL

ALLEN BRADLEY 1775-A1 USPP 1775A1

INDRAMAT CLM01.3-X-0-2-0-FW USPP CLM013X020FW

XYCOM 9487-27B2118050000 USPP 948727B211805000

TYCOR PTY4803Y6515F NSFP PTY4803Y6515F

HOFFMAN A-42SA3810LP USPP A42SA3810LP

Siemens 6ES5-242-1AA13/6ES5242-1AA13 COUNTER MODULE XLNT

SIEMENS 6ES5 375-1LA41 MEMORY MODULE

SIEMENS Digital Input Module 6ES5 434-7LA11

Siemens 6ES5 998-0UB53 NSFP 6ES59980UB53

Siemens 6ES5464-8MC11 6ES5 464-8MC11

SIEMENS MP277-10 6AV6 643-0CD01-1AX1 Touch Glass

Reliance Electric 0-57416-K Remote I/O Comm Mod Missing Mounting Clip

Texas Instruments 500-5037A

Square D Modified Differential Ground Fault Interface Module S48891

UPGRADED CISCO1841-HSEC/K9 ROUTER WITH 1YR 1841-HSEC/K9

Siemens CABLE 6ES7 901-0BF00-0AA0 HMI MPI to S7-300

Modicon AS-W903-015

Schneider Modicon AOUTMATION TSX COMPACT DEP 218/AS-BDEP-218

Schneider Modicon HS Counter Module AS-B883-001

Schneider Modicon AS-BDAP-253 NSFP ASBDAP253

Schneider Modicon AS-B885-121

Schneider Modicon /Gould AS-P453-632 Remote I/O Module (UVG)

Schneider Modicon CHASSIS RACK AS-H819-209 AS-9534-02

SCHNEIDER Modicon TSXDSZ08R5

SCHNEIDER TSX QUANTUM ANALOG INPUT MODULE 140 AVI 030 00 043 502 753

Redback AIM-1K-2OC3SM VAC1DEOAAA SMS 1800 2 Port OC3 SM 90 Free Ship

SIEMENS 6ES5-470-4UA13/6ES5470-4UA13 OUTPUT MODULE XLNT