How can you diagnose an electrical control system producing incorrect setpoints?

2 Check the logic

The next step to diagnose an electrical control system producing incorrect setpoints is to check the logic that processes the inputs and generates the setpoints. The logic may be implemented in hardware, software, or both, depending on the type and complexity of the system. You should inspect the logic for any errors, faults, or glitches that may cause the setpoints to deviate from the desired values. You can use a debugger, a simulator, or a code analyzer to examine the logic and trace the flow of data and commands.

3 Check the outputs

The third step to diagnose an electrical control system producing incorrect setpoints is to check the outputs that actuate the system. These outputs may include motors, valves, relays, or other devices that control the physical variables of the system. You should verify that the outputs are working correctly, that they are receiving and responding to the setpoints, and that they are not affected by external factors such as noise, interference, or wear and tear. You can use a multimeter, an oscilloscope, or a power analyzer to test the outputs and measure their performance and efficiency.

4 Check the feedback

The fourth step to diagnose an electrical control system producing incorrect setpoints is to check the feedback that monitors the system. The feedback may include sensors, indicators, alarms, or other devices that measure or display the actual output of the system. You should verify that the feedback is accurate, reliable, and consistent with the setpoints and the outputs. You can use a multimeter, an oscilloscope, or a data logger to record and analyze the feedback and compare it with the expected results.

5 Check the parameters

The fifth step to diagnose an electrical control system producing incorrect setpoints is to check the parameters that configure the system. These parameters may include gains, offsets, limits, or other values that affect the behavior and performance of the system. You should verify that the parameters are set correctly, that they are compatible with the system specifications and requirements, and that they are not altered or corrupted by unauthorized or accidental changes. You can use a configuration tool, a user interface, or a parameter file to access and modify the parameters and restore them to their original or optimal values.

6 Check the environment

The sixth and final step to diagnose an electrical control system producing incorrect setpoints is to check the environment that surrounds the system. The environment may include temperature, humidity, vibration, or other conditions that influence the operation and stability of the system. You should verify that the environment is within the acceptable range, that it is not causing any damage or deterioration to the system components, and that it is not interfering with the system signals or functions. You can use a thermometer, a hygrometer, an accelerometer, or other instruments to measure and control the environment and ensure that it is suitable for the system.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?