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DCS系統(tǒng)在工業(yè)生產(chǎn)過程的廣泛應(yīng)用，使可靠性、穩(wěn)定性問題更加突出，也使人們對整個系統(tǒng)要求越來越高。人們希望DCS系統(tǒng)盡量少出故障，又希望DCS系統(tǒng)一旦出現(xiàn)故障，能盡快診斷出故障部位，并盡快修復(fù)，使系統(tǒng)重新工作。下面簡單介紹故障大體分類及故障診斷的一般方法。
　　一、DCS系統(tǒng)故障的分類
　　為了便于分析、診斷DCS系統(tǒng)故障發(fā)生的部位和產(chǎn)生原因，可以把故障大致分為如下幾類。
　　1、現(xiàn)場儀表設(shè)備故障
　　現(xiàn)場儀表設(shè)備包括與生產(chǎn)過程直接聯(lián)系的各種變送器、各種開關(guān)、執(zhí)行機(jī)構(gòu)、負(fù)載等?，F(xiàn)場儀表設(shè)備發(fā)生故障，直接影響DCS系統(tǒng)的控制功能。在目前的DCS控制系統(tǒng)中，這類故障占絕大部分。這類故障一般是由于儀表設(shè)備本身的質(zhì)量和壽命所致。
　　2、系統(tǒng)故障
　　這是影響系統(tǒng)運行的全局性故障。系統(tǒng)故障可分為固定性故障和偶然性故障。這類故障一般比較明顯且影響也是局部的，它們主要是由使用不當(dāng)或使用時間較長，模板內(nèi)元件老化所致。
　　3、硬件故障
　　這類故障主要指DCS系統(tǒng)中的模板(特別是I/O模板)損壞造成的故障。這類故障一般比較明顯且影響也是局部的，它們主要是由使用不當(dāng)或使用時間較長，模板內(nèi)元件老化所致。
　　4、軟件故障
　　這類故障是軟件本身所包含的錯誤所引起的，軟件故障又可分為系統(tǒng)軟件故障和應(yīng)用軟件故障。系統(tǒng)軟件是DCS系統(tǒng)帶來的，若設(shè)計考慮不周，在執(zhí)行中一旦條件滿足就會引發(fā)故障，造成停機(jī)或死機(jī)等現(xiàn)象。此類故障并不常見。應(yīng)用軟件是用戶自己編定的。在實際工程應(yīng)用中，由于應(yīng)用軟件工作復(fù)雜，工作量大，因此軟件錯誤幾乎難以避免，這就要求在DCS系統(tǒng)調(diào)試及試運行中十分認(rèn)真，及時發(fā)現(xiàn)并解決。
　　5、操作、使用不當(dāng)造成故障
　　在實際運行操作中，有時會出現(xiàn)DCS系統(tǒng)某功能不能使用或某控制不封不能正常工作，但實際上DCS系統(tǒng)并沒有毛病，而是操作人員操作不熟練或操作錯誤所引起的。這對于初次使用DCS系統(tǒng)的操作工較為常見。

GENERAL ELECTRIC IC3600SSVD1H USPP IC3600SSVD1H

TEXTRON P8387-400011-51 USPP P838740001151

ADEPT TECH 10315-00940 USPP 1031500940

WESTINGHOUSE A200M4CAC USPP A200M4CAC

Siemens 6ES5-456-7LB11 NSFP 6ES54567LB11

SIEMENS 6ES5-101-8UU43 USPP 6ES51018UU43

Siemens 6ES5 375-1LA21 Memory Submodule 16k

Siemens S5 PLC 6ES5 441-7LA11 Output 32 Way

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 1/4" Air Filter Regulator 91F60 Airco 03340-60

ALLEN-BRADLEY DATALINER OPERATOR INTERFACE CAT2706-D21J8

A-B NIPPONDENSO 8500-A2D-L1B AC Servo Motor [PZ4]

AC Motor Inverter - 60 HP - 600 Volt - Three Phase Input

A06B-0572-B372#7076 FANUC SERVO MOTORS REMANUFACTURED

750 kVA Transber OLSUN Electronics 12470-480/277 - Built in 02/97 Indoor Dry

RELIANCE ELECTRIC DSA-MTR-60D USPP DSAMTR60D

ALLEN BRADLEY 5130-KAA USPP 5130KAA

ALLEN BRADLEY 200042 NSPP 200042

INDRAMAT HDS03.2-W100N-HS76-01-FW USPP HDS032W100NHS760

YASKAWA ELECTRIC CACR-SR30-TZ6SM USPP CACRSR30TZ6SM

WEST ELECTRONICS M-3800 NSPP M3800

HONEYWELL TC-CCR012 NSFP TCCCR012

Siemens 6ES5-244-3AA11 USPP 6ES52443AA11

SIEMENS 6ES5 376-1AA21 SUB-MEMORY MODULE IN BOX

SIEMENS Input Module 6ES5 436-4UB12 SURPLUS Opened Box

Siemens Adaption Casing 6ES5-491-0LA12 17790

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

SIEMENS MP370 12.1" 6AV6545-0DA10-0AX0 Touch Screen Display Glass

Reliance AutoMax SA 500 AC power module servo amplifier 615055-1S

Texas Instruments 505-4316

Statec Magnetic Memory Interface Module PPS8500DSS2C2

UC520-16U-4FXO-K9 CISCO 16U CME BASE CUE PHONE FL W/4FXO 1VIC

Siemens Contactor 3TF35-11 3TF3511 3TF35-11-0XM0 AC220V in Box

Modicon AS-W978-050

Schneider Modicon Pat Harrington Jr as from One Day At A Time 8X10 PHOTO 1

Schneider Modicon AEG/GOULD/MODICON/ AS-C484-265 MAINFRAME CONTROLLER RFB

Schneider Modicon AS-BDEP-013 NSPP ASBDEP013

Schneider Modicon AS-BDAP-216 Compact Out Module ASBDAP216

Schneider Modicon -AS-2184-011

Schneider Modicon DAP 216 / AS-BDAP-216 DISCRETE OUTPUT CARD MODULE 16 X 24 VDC

Schneider PLC 140 ACO 13000 140ACO13000 NIB Sealed

SCHNEIDER MODICON TSX QUANTUM 24VDC SOURCE INPUT MODULE 140 DDI 353 10

QY22 Mitsubishi PLC 16 Point Triac Output Card

SIEMENS 6ES5-456-4UA12/6ES5456-4UA12 DIGITAL OUTPUT MODULE NIB

SIEMENS SINUMERIK 6FC5203-0AF02-0AA1 MembraKeypad - OP012 free ship

MITSUBISHI COMMUNICATION MODULE A1SJ71QC24N R2 RS-232-C

SIEMENS SIMODRIVE 6SN1118-0DM21-0AA0 6SN11180DM210AA0

SIEMENS SINUMERIK CONTROL DRIVE MODEL 6FC 3451 OJA Z

SIEMENS 3Wa

Allen-BradleyPanelView 1200 Operator Interface 2711-TC1

Allen Bradley SLC 500 1746-OB32 Ser D 1746-0B32 Output Module

ABB robot, Fanuc robot, Motoman robot, Nachi robot,

A06B-0143-B188 FANUC SERVO MOTORS REMANUFACTURED

0190-09379 wPCB ASSY VME CPU SYNERGY UPGRADED

MTS SYSTEMS CO MPAZ-100-460-206 USPP MPAZ100460206

ALLEN BRADLEY 1756-L1M1 FNFP 1756L1M1

ALLEN BRADLEY 1336-B010-EAD-FA2 USPP 1336B010EADFA2

GENERAL ELECTRIC 502997 USPP 502997

SQUARE D PA360000M USPP PA360000M

SIEMENS 6SE3217-3DB40 NSPP 6SE32173DB40

AUTOMATION INTELLIGENCE 8207D82 USPP 8207D82

Siemens 6ES5 944-7UB11 -- 6ES59447UB11

Siemens Simatic S5 6ES5 526-3LF01 6ES55263LF01

SIEMENS 6ES5-701-1LA12 NSFP 6ES57011LA12

Siemens 6ES5 482-4UA20/6ES54824UA20 I/O Ver 02 SEALED OFFERS ACCEPTED

Siemens 6AV3503-1DB10 OP3 ping Worldwide

Siemens Inverter 6SE6420-2UC25-5CA1 6SE64202UC255CA1 in Box

Sans Digital HA-ARC-ARC1223X 2-Port Mini-SAS 6G SAS/SATA PCIe 2.0 x8 Controller

Superior Electric M063-FD09

SIEMENS Interface Module 6ES5 752-0AA43 WITH PAPERWORK

SER C F/W REV A PKG DATE 07/18/2011

Siemens 6SE7028-0ES87-2DA1 6SE7 028-0ES87-2DA1 FreeShip

Siemens USB/PPI+ USB PPI+ PLC Cable 6ES7 901-3DB30-0XA0

Schneider Modicon AS-BDEP-209 ASBDEP209 8 AC Input NIB

Schneider Modicon ASB875111 Analog Input Module AS-B875-111

Schneider Modicon AS-B840-108 USPP ASB840108

Schneider Modicon AS-B258-101 Analog MUX Mercury Relay 0 To 10 V B258-101

Schneider Modicon B872 4-20MA ANALOG CURRENT OUTPUT MODULE AS-B872-100 NO TERMINAL

Schneider Modicon AS-H827-107/ASH827107 Chassis Rack

SCHNEIDER MODICON TC2000 INDUSTRIAL PC OPERATOR INTERFACE 3515 KPM CASE BACK

Siemens 6ES5420-4UA13 Digital Input Module 32 DI 24VDC SIMATIC with Warranty

ROBOTRON 503-1-0324-07 USPP 5031032407

SIEMENS BREAKERS P/N: 1EC 60947 VDE 0660

SIEMENS Sinumerik CPU Slave 6FX1111-0AN02 E Stand E & 00

RELIANCE ELECTRIC AUTOMAX NETWORK COMMUNICATIONS MODULE 0-57404-1E

SIEMENS CONTROLLER CARD 6SN1118-0DM33-0AA0

SIEMENS 6SN1118-1NH01-0AA1 6SN1 118-1NH01-0AA1 SIMODRIVE 611-U Control Unit

SIEMENS 6FC5-110-0BB01-0AA1

AllenBradley2711P-RDT7C/C2711PRDT7CPanelviewPlus

ALLEN BRADLEY VersaView 1500M OPERATOR INTERFACE DISPLAY 6186-M15AL SER. B

ABB IEPAS02 SEAL DATE 11-29-10 POWER SUPPLY SEALED

ADVANCED ENERGY MDX DC power supply, lots of 7

(N2-3) 1 ROBOTRON 323-0-0102-00 CONTROLLER N2-3

MEASUREX 053669-01 USPP 05366901

ALLEN BRADLEY 1336-B050-EAG-FA2-L2-S1 USPP 1336B050EAGFA2L2

GE FANUC IC600LX680 USPP IC600LX680

FANUC A16B-0160-0471 USPP A16B01600471

SIEMENS 6AV7-500-0BA00-0AA0 NSFP 6AV75000BA000AA0

RELIANCE ELECTRIC 2GU42001 USPP 2GU42001

SIEMENS 6ES7-315-2EG10-0AB0 USPP 6ES73152EG100AB0

Siemens 6ES5 470-4UB12 6ES54704UB12

Siemens 6ES5-945-7UA13 USPP 6ES59457UA13

SIEMENS 6ES5-440-8MA11 USPP 6ES54408MA11

Siemens 6ES5 777-0BB01 SINEC L1S5 BT 777

Siemens S5 6ES5 944-7UA12 6ES59447UA12

Siemens C98043-A1052-L1 03

SIEMENS 6ES5 482-8MA13 DIGITAL I/O MODULE

Square D 8020 SMM-710

Omega IM-Loader2 PC to Module Interface Cable

WS-C3560-24TS-S Cisco Cat 3560 SWITCH 24 10/100 2 SFP SLOTS

Siemens 6ES7314-1AF10-0AB0 6ES73141AF100AB0

Siemens Simodrive 6SE1200-1GA36-2

Reliance Motomatic II

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

Schneider Modicon AS-B545-000 USPP ASB545000

Schneider Modicon AS-W513-010 USPP ASW513010

Schneider Modicon AS-BDEP-210 ASBDEP210

Schneider Modicon AS-B825-016 24vdc Input Module XLNT

MODICON AS B828-016 OUTPUT MODULE 5VDC 16 PT

Siemens HTRI-D Addressable Dual Input Module- for FS-250 XLS

SHARP ZW-162N USPP ZW162N

SIEMENS OPERATOR INTERFACE PMU 6SE7090 0XX84 2FA0 2FAO

SIEMENS Sinumerik 6EV3053-0DC. Power Supply Module.

TEKTRONIX TDS2CMA Communication Module TESTE

SIEMENS 6SN1118-0NH00-0AA2 6SN11180NH000AA2

SIEMENS Simatic Simodrive Card C98040-A1087. .

SIEMENS 6FC5303-0AA02-0AA0 HANDWHEEL CONNECTION MODULE XLNT

Advantech POS-562 REV.A1

Allen-Bradley 1746-NO4V SLC 500 4-Ch Analog OUTPUT Module

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 88138

ADEPT TECH 10330-15350 USPP 1033015350

(000 no lot) Fanuc PLC 10 s rack 7cards IC693CHS391C IC693CPU331S . PRISTINE

INDRAMAT CLM01.3-X-0-2-B-FW USPP CLM013X02BFW

TELEMECANIQUE ATV-58HD33N4ZU NSPP ATV58HD33N4ZU

EDWARDS MC4160-C14 NSFP MC4160C14

CUTLER HAMMER 92005401 USPP 92005401

PHOENIX CONTACT IBS-ISA-SC/486DX/I-T NSFP IBSISASC486DXIT

MODICON AS-521P-008 NSPP AS521P008

HONEYWELL 51305508-200 USPP 51305508200

Siemens 6ES5 312-3AB12 6ES53123AB12

Siemens 6ES5-526-3LF11 NSFP 6ES55263LF11

SIEMENS 6ES5-373-1AA61/6ES5373-1AA61 MEMORY SUBMODULE NIB

Siemens 6ES5 306-7LA11 -- 6ES53067LA11

Siemens 6ES5-490-7LB21

Siemens 6GK7443-1BX00-0XE0 in Box

Siemens TP27 HMI 6AV3627-1QL00-0AX0 6AV36271QL000AX0

Siemens 6ES5927-3SA11

Lenel LNL-1300 Single Reader Interface Module

Yaskawa 87820-15003-S202 PLC Module 8782015003 NIB

SIEMENS 6ES7 223-1HF00-0XA0 in Sealed Box

Siemens OP37 6AV3637-1LL00-0FX1 Membrane Keypad ping Worldwide

Reliance 0-49002-2

Schneider Modicon AS-B805-016 800 I/O MODULE NIB

Schneider Modicon AS-884A-311 USPP AS884A311

Schneider Modicon AS-P230-080 USPP ASP230080

Schneider Modicon AS-B266-000 USPP ASB266000

Schneider Modicon AS-8534-000 Low Density Connector NIB

MODICON TELEMECANIQUE MAGELIS OPERATOR INTERFACE XBT F024110

SIEMENS SIMATIC S7 DIGITAL INPUT MODULE 6ES7 321-1BH02-0AA0 6ES7321-1BH02-0AA0

Siemens 6ES7 334-0KE00-0AB0 -- 6ES73340KE000AB0

Siemens Simatic Panel PC IL70 Touch Panel PC 6AG7011-1BA00-0AD0

Siemens 9350 9350DC-100-0NZZZA NIB Power Meter Display ION Profibus Access

SIEMENS Sinumerik MachiControl Panel 3T 548 025 9004

SIEMENS 6SN118-0AA11-0AA1 6SN11180AA110AA1 Simodrive

SIEMENS SIMODRIVE 6SN1123-1AA00-0HA0 with 6SN1118-0AD11-0AA0

SIEMENS Encoder 6FC9320-3DC F54621B00

Advantech PCM-9381

ALLEN-BRADLEY 2711E-K10C6 PANELVIEW 1000E OPERATOR INTERFACE

ABB 6228BZ10000D MULTIBUS SC D/F

Acterna FST-2310

6AV6112-1AB20-0DB0 COROS VP-B20

8520-MOP7 ALLEN BRADLEY MONITORS CRT REMANUFACTURED

SIEMENS 6SE3-228-4DK40 USPP 6SE32284DK40

BAILEY CONTROLS IMCOM-03 NSFP IMCOM03

ASEA BROWN BOVERI YB560103-CD/24 USPP YB560103CD24

MODICON 557VIC10400 USPP 557VIC10400

INDRAMAT MDD093A-N-030-N2L-110PB0 USPP MDD093AN030N2L1A

ASEA BROWN BOVERI GNT0137211P5 USPP GNT0137211P5

TYLAN GENERAL FC-3926V NSFP FC3926V

Siemens 6ES5-450-3AA11 USPP 6ES54503AA11

SIEMENS 6ES5 700-0LA12 6ES57000LA12

SIEMENS S5 6ES5 374-2KH215V Flash 256 kByte Memory 16Bit

Siemens S5 6ES5 955-3LF44 6ES5955-3LF44 6ES59553LF44

Siemens 6ES7 972-0BA51-0XA0 6ES79720BA510XA0 NIB

Siemens S7 CP443-5 Simatic 6GK7 443-5DX04-0XE0 FreeShip

Siemens 3LC5 277-1TB

Honeywell Intrusion 4100SM Serial Interface Module

WATERS HPLC SYSTEM INTERFACE MODULE

Siemens 6DS1731-8EA 6DS17318EA in Box, Seal opened,

Siemens LOGO! 24RCL PLC 6ED1053-1HB00-0BA2

Omron 3G2A5-RT002-E

Schneider Modicon AS-M480-004 ASM480004 4K Memory Carteidge

Schneider Modicon PCB Processor AS-500P-000 Rev B16 _ Assy S500 Rev B Circuit Board

Schneider Modicon AS-H827-003 USPP ASH827003

Schneider Modicon Groupe/Schneider/ AS-B804-016 unsed warranty

Schneider Modicon AS-BDEP-218

Schneider Modicon SA-B575-202 Stepper Motor Control AS-IS

Telemecanique Megelis HMI XBTG2220 Operator Interface

SCHNEIDER Telemecanique Switch XB4 BVB3

SIEMENS XBTGT1105 3.8" Touch Panel XLNT

Siemens 6AV6 542-0AD15-2AX0 MP270 Simatic Multi Panel

SIEMENS SINUMERIK 6FC5203-0AF02-0AA1 MembraKeypad

GE Fanuc A16B-3200-0331 Ethernet Communications Module Card