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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。

Modicon/Schneider PanelMate PM+ 1000 Modbus MMPMMP003C

Siemens Input Module 6ES5430-4UA13 430-4UA13

Schneider TSX AEY420 Analog Input Module Modicon TSXAEY420

RME HDSPEMADI 24Bit 96K Channel PCIE Card

Siemens Simatic OP37 Operator interface Computer 6AV3637-1MLOO-OFXO

SIEMENS Sinumerik 6FX1126-0BL01 Module

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 AS-BADU-206 TSX Compact Analog Input

Schneider Modicon DEP 216 / AS-BDEP-216 Input Module

Schneider Modicon AS-BDAP-252 NSFP ASBDAP252

Schneider Modicon AS-B885-111

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

Schneider Modicon CARD AS-B559-001 ASB559001 B559

Schneider Modicon TSXCFY11 TSX CFY 11 in Box

SCHNEIDER TSX QUANTUM RTD INPUT MODULE 140 ARI 030 10 20-100414-01

Redback CM-M-512MB Connection Manager BAC8GMBEAA

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

SIEMENS FANUC SINUMERIK PRIMO SG CONTROLLERPARTS

Mitsubishi Melsec A1SJ71QC24N Serial Communication Module

SIEMENS Simodrive 6SN1114-0AA01-0AA0 Module

SIEMENS Sinumerik I/0-Modul 6FC3984-3RA

SIEMENS 6FC7 = ECC89 = 6N24P HF Double Triode Tubes NOS OTK Voskhod SAME DATE 24pc

AllenBradley1746-NO4I/A1746-N04ISLC500AnalogOutputModule

ALLEN BRADLEY SLC 500 ANALOG OUTPUT MODULE 1746-N04I

ABB ROBOT SERVO 3HAC 10555-1

A06B-0143-B088#0008 FANUC SERVO MOTORS REMANUFACTURED

0020-27712 CLAMP RING 6" JMF PADDED HOT AL HTHU

MODICON P1-984A-816 NSFP P1984A816

ALLEN BRADLEY 150-B180NBDB-8L USPP 150B180NBDB8L

ALLEN BRADLEY 1326AB-B515E-21-K5 USPP 1326ABB515E21K5

GENERAL ELECTRIC 193X-451AAG03 USPP 193X451AAG03

SQUARE D AF2308GETBMB USPP AF2308GETBMB

SIEMENS 6SC6-100-0GA12 USPP 6SC61000GA12

ASEA BROWN BOVERI 3HAB2209-1 USPP 3HAB22091

Siemens 6ES5 943-7UB11 6ES59437UB11

Siemens Simatic S5 6ES5 340-3KB42 6ES53403KB42

SIEMENS 6ES5-700-2LA10 USPP 6ES57002LA10

Siemens 6ES5 454-4UA12/6ES54544UA12 SEALED

SIEMENS 64K MMC 6ES7953-8LF11-0AA0

Siemens GSM Modem TC35i

SATT CONTROL 492-705-502 USPP 492705502

Square D EQ5138-G1

SIEMENS DEMATIC F0038-00146 SLUG RELEASE INTERFACE MODULE

SynchLink Drive Interface Module QTY

Siemens 6SE7014-0TP50-Z NIB

Siemens TP7 6AV3607-1NH00-0AX0 Touch Panel

Schneider Modicon DISCRETE OUTPUT 8 PT MODULE DAP 210 AS-BDAP-210 2

Schneider Modicon ASBADU204 Compact Analog Input AS-BADU-204

Schneider Modicon AS-B833-016 USPP ASB833016

Schneider Modicon PLC MODULE AS-B875-102 ASB75102 S51C

Schneider Modicon AS-WBXT-201 Bus Extension Cable

Schneider Modicon AS-H819-209 - 7 Slot Chassis 984 Series Rack

Schneider PLC Analog Output Module 170AAO12000 NIB

SIEMENS 6ES5430-4UA14 INPUT MODULE XLNT CONDITION LNC

roland prelude 61 key keyboard in VG CONDITION

Siemens Coros Op 15 6AV3515-1EB00

SIEMENS SINUMERIK 840D/DE NCU 573.4 6FC5357-0BB34-0AA0 6FC53570BB340AA0 NIB

Reliance Electric Network Communications Module 57404-2

SIEMENS Control Board Servo Drive 6SN-01118-OAA11-OAA1

SIEMENS P/N 3-720-0229A SIMODRIVE MODULE

SIEMENS 6FC5110-0DB02-0AA2 6FC51100DB020AA2 BOARD MODULE VER T

ALLENBRADLEY2711P-T9C1OPERATORINTERFACEPANELVIEW900SERIESCREVC

Allen Bradley VersaView 1500W 6180W-15KSXPH Operator Interface Panel

ABB F4S3200 MEGAMAX SACE-F4 3200A 690V, PR1/P LSIG Trip, Ctrl PR1/C F4S 3200 Amp

Advanced Energy AE, Pulsed Plasma PDP 2500 RF Generator

(L26-5) 1 SCHNEIDER AUTOMATION MM-PMC2-40-SC W/O OPERATOR INTERFACE L26-5

MARCONI ASX-1000-10AC NSFP ASX100010AC

ALLEN BRADLEY 1326AB-B740E-21 USPP 1326ABB740E21

GE FANUC IC3600EPSU1 USPP IC3600EPSU1

FANUC A06B-6058-H011 NSPP A06B6058H011

SIEMENS 1FT6064-6AF71-3EH1-Z NSPP 1FT60646AF713EH1

RELIANCE ELECTRIC 0-57411-2 NSFP 0574112

SIEMENS 3VF6212-1MK44-0AA0 NSFP 3VF62121MK440AA0

Siemens 6ES5 466-3LA11 6ES54663LA11

Siemens 6ES5-943-7UB11 NSFP 6ES59437UB11

SIEMENS 6ES5-435-6AU11 NSFP 6ES54356AU11

Siemens 6ES5 700-8MA11 BUS MODULES5 REFURBIS

Siemens S5 6ES5 921-3WB11 6ES59213WB11

Siemens C7-634 6ES7634-1DF02-0AE3 Membrane Keypad

SIEMENS 6ES5-308-3UA12 NSFP 6ES53083UA12

Square D 8020 SCP-311

NOTIFIER 2-Wire Detector Interface Module MMX-2

WS-C4506-E CISCO

Siemens 6ES7231-0HC21-0XA0 6ES72310HC210XA0 FreeShip

SIEMENS SIMATIC PANEL PC 870 PC870 6AV7 743-2AC00-0AA0 Membrane Keypad

Reliance 612404-7R

Schneider Modicon DAP 210 / AS-BDAP-210 89 PT OUTPUT MODULE

Schneider Modicon AS-B373-000 USPP ASB373000

Schneider Modicon AS-T190-000 USPP AST190000

Schneider Modicon AS-BDAP-209 PLC

Schneider Modicon AS-B824

MODICON AS-B572-010 OUTPUT MODULE 0-10V ANALOG

Siemens Input Module 6ES5420-7LA11

SIEMENS 6DD1641-0AC0 EB11 DIGITAL I/O MODULE

Siemens Output Module 6ES5441-7LA11 ""

SIEMENS SIMADYN S5 MODULE PN 6DD2920-0A00

Texas Instruments 500-2109 Communication Module Assembly

SIEMENS 6SN1118-0DM11-0AA1 6SN11180DM110AA1

SIEMENS SIMODRIVE 1P 6SN1123-1AA01-0FA1

SIEMENS 6FC5357-0BB15-0AA0 6FC5 357-0BB15-0AA0 SINUMERIK 840D/DE NCU 571.5

ADVANTECH PCM-3730 in Box

Allen-Bradley 1747-L532 SLC 5/03 CPU with I/O modules

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 84802

ADEPT TECH 10310-61210 USPP 1031061210

(#3069) Allen-Bradley 1756-EN2T ControlLogix Ethernet Module Factory Sealed

HORIBA FIA-23A USPP FIA23A

TB WOODS WFC4025-0C NSFP WFC40250C

DEMATIC KBF100-4-8/2 NSFP KBF100482

COOPER INDUSTRIES 927255 NSPP 927255

PACIFIC SCIENTIFIC SC723B001-01 USPP SC723B00101

MODICON AM-S985-032 USPP AMS985032

GRAPHTEC WR3300 USPP WR3300

Siemens 6ES5 308-3UB11 -- 6ES53083UB11

Siemens 6ES5-524-3UA15 NSFP 6ES55243UA15

SIEMENS 6ES5-372-0AA61 NSFP 6ES53720AA61

Siemens 6ES5 103-8MA03 CPU MODULE

Siemens 6ES5-373-1AA41 32K Memory 6ES53731AA41 6ES5373-1AA41 N330

Siemens 6GK7 343-5FA01-0XE0 6GK7343-5FA01-0XE0 CP343-5

Siemens TP177B 6AV6642-0BA01-1AX1 Touch Glass + Film

Siemens 6ES5701-1LA12

KV1517A KVM Extender Black Box ServSwitch Summit Computer Interface Module

YASKAWA ELECTRIC JAMSC-B1074-1 USPP JAMSCB10741

SIEMENS 6ES7 222-1HF21-0XA0 6ES7222-1HF21-0XA0 FreeShip

Siemens OP277 6AV6643-0BA01-1AX0 Membrane Keypad

Red Lion LIBC1E00

Schneider Modicon AS-B821-108 ASB821108 Input Module

Schneider Modicon AS-884A-101 Processor Module 60 DAY WARRANTY

Schneider Modicon AS-P120-000

Schneider Modicon AS-B236

Schneider Modicon AS-516P-007 Processor Board Rev C16 AIND/UVG

Modicon XBTF024110 Magelis Operator Interface XBT F024110 24VDC 35W V1.1 3244

Siemens Simatic s7-300 analog input module 6ES7 331-7KB02-0AB0

TELEMECANIQUE TSX-AEY-1600 TSXAEY1600

Siemens Simatic S5 6ES5 441-8MA11 Digital Output Module

Siemens 9610 9610EH-1156-JZZB NIB Power Meter Display ION Ethernet Access

SIEMENS Sinumerik FM 6FC5210-0DA00-1AA1 6FC5 210

SIEMENS 6SN1118-0DM33-0AA2 6SN11180DM330AA2 Servo

SIEMENS Simodrive 6SN1123-1AB00-0AA0 LT-MODUL Version A

SIEMENS I/O MUDULE BOARD 64EY32AUSGAENGE 6FC3984-3RA USMT CNC

Advantech PCM-3641 4-port RS-232 High-Speed Module FS

ALLEN-BRADLEY 2711-k6C2L1 PANELVIEW 600 TOUCH SCREEN TESTED

ABB 58031844 Mem86-3 192K AB Stromberg

ACOPOS SERVO DRIVE BV1320.00-2 SELLING AS IT IS

AAT-AAT1105A-T1-T SOP IC Original Packing

8510A-A11-A2 ALLEN BRADLEY CONTROLLERS REMANUFACTURED

SIEMENS 6RY1-243-0AA00 USPP 6RY12430AA00

ATLAS COPCO ETD-S7-50-13-CTADS USPP ETDS75013CTADS

ASEA BROWN BOVERI DCS502-B02505121 USPP DCS502B02505121

MITSUBISHI MR-J2S-11KB NSFP MRJ2S11KB

INDRAMAT MAC112D0ED1B130 USPP MAC112D0ED1B130

APW MCLEAN M17-0216-G009H USPP M170216G009H

TEST PRODUCTS T73879 NSPP T73879

Siemens 6ES5-440-5AA11 USPP 6ES54405AA11

SIEMENS 6ES5 482-8MA13

SIEMENS S5 6ES5 267-8MA11 6ES52678MA11

Siemens S5 6ES5 450-8MB11 Digital Output Module

SIEMENS 6ES7 621-1AD01-0AE3 C7-621 99%

Siemens RWX62.734/509 Controller

PreSonus FireStudio Firewire Mobile Studio Interface Bundle Extended

Honeywell 51400955-100 DCS Process Network Interface Board Module Card

Volvo V70 S60 01-06 GROM USB interface car module Bluetooth AUX iPhone VOL01U2P

Siemens 6DD1607-0CA1 6DD1 607-0CA1 in Box

Siemens LOGO! 12/24RC 6ED1052-1MD00-0BA6 NIB

Omron 3G2A5-MP00

Schneider Modicon AS-P120-000/ASP120000 Power Supply SEALED

Schneider Modicon BOARD AS-521P-011 REV 35 /REPAIRED

Schneider Modicon AS-H819-007 NSFP ASH819007

Schneider Modicon Gould/ AS-2802-000

Schneider Modicon AS-BDAP-216

Schneider Modicon Quantum 140CPS11420 Power Supply AS-IS

Telemecanique Digital Operator Panel VL 1006366598

Schneider Telemecanique Modicon TSX3721001

Siemens6ES5-452-8MR11Output Module 4POINT 24VDC

Siemens 6AV6 545-0BA15-2AX0 6AV65450BA152AX0 Panel

SIEMENS Sinumerik 6FC5110-0DB01-0AA1 E.Stand J CPU Interface Module

GE FANUC ENHANCED COMMUNICATION MODULE IC693CMM302F

SIEMENS WARRANTY Control Board w/ 6SN1114-0AA01-0AA0

SIEMENS SINUMERIK 3/800 6FC3988-7AH20 TESTED WARRANTY

SIEMENS MOORE 115300-11 350 INDICATING STATION PROGRAM CARD PCB

ALLEN-BRADLEY DATALINER OPERATOR INTERFACE CAT2706-D21J8

A-B NIPPONDENSO 8500-A2D-L1A Motors-AC Servo [PZ4]

AC Motor Inverter - 60 HP - 480 Volt - Three Phase Input

A06B-0571-B072#7008 FANUC SERVO MOTORS REMANUFACTURED

750 kva Square D Transformer HV 4160 3 LV 416Y/240 & 600a HVL Switch

RELIANCE ELECTRIC DSA-MTR-60D NSPP DSAMTR60D

ALLEN BRADLEY 506309 NSPP 506309

ALLEN BRADLEY 1791-IOVW USPP 1791IOVW

INDRAMAT HDS03.2-W075N-HS12-01-FW USPP HDS032W075NHS120

YASKAWA ELECTRIC CACR-SR15SZ1S-SY22 USPP CACRSR15SZ1SSY22

WELDING TECHNOLOGY CORP WI03-T13B USPP WI03T13B

HONEYWELL STF128-R1H-04530-S1-F1C3-714B USPP STF128R1H04530S1

Siemens 6ES5-243-1BA11 USPP 6ES52431BA11

SIEMENS 6ES5 376-1AA21 SUB-MEMORY MODULE

SIEMENS Input Module 6ES5 436 4UB12 SURPLUS

Siemens Adaption Casing 6ES5 491-0LB11 33422

Siemens 6ES6400-0EN00-0AA0 Micromaster Encoder FreeShip