How quickly can faults be resolved?

Resolution time depends on the issue, but our structured approach ensures faults are identified and resolved as quickly and efficiently as possible.

Can you support legacy systems?

Yes, we specialise in diagnosing, maintaining, and supporting legacy automation systems.

What are common causes of automation failures?

Common causes include hardware faults, wiring issues, software errors, communication failures, and poor documentation.

What is industrial automation fault finding?

Industrial automation fault finding involves diagnosing and resolving issues within PLC systems, control panels, SCADA platforms and industrial machinery to restore reliable operation.

What causes recurring automation faults?

Recurring automation faults are often caused by ageing hardware, inconsistent programming, poor documentation, wiring issues or unresolved system integration problems.

Can fault finding reduce downtime?

Yes. Structured fault finding improves diagnostic speed, identifies root causes and helps reduce repeated failures that contribute to production downtime.

Do you support legacy automation systems?

Yes. Stratos supports both modern and legacy automation systems, including obsolete PLC platforms and ageing industrial control infrastructure.

Do you provide on-site automation support?

Yes. Stratos provides on-site diagnostics, troubleshooting and automation support services for industrial and manufacturing environments across the UK.

Fault Finding & Maintenance Support UK

Designing, manufacture and building control panels with our expert engineers

When automation systems fail, every minute matters.

At Stratos Control Systems, we provide rapid, structured fault finding and maintenance support for industrial automation systems, helping businesses identify faults quickly, restore operation, improve labelling and prevent repeat failures.

Recurring faults are often linked to poor panel layout, undocumented modifications or ageing hardware, which can be addressed through professional control panel redesign and manufacturing.

We diagnose issues across PLC systems, control panels, SCADA systems, and machine control systems, delivering practical solutions that get your system back online fast.

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Why Automation Faults Keep Returning

Recurring automation faults are often symptoms of wider issues rather than isolated failures. Poor documentation, ageing hardware, inconsistent PLC programming, inadequate diagnostics and outdated control panels can all contribute to repeated breakdowns and unnecessary downtime.

At Stratos, we don't just restore systems to operation. We identify the root cause of the problem and recommend practical improvements that help reduce repeat failures and improve long-term reliability. Where necessary, we can also recommend Control System Upgrades, PLC Upgrades & Migration or Control Panel Refurbishment to resolve underlying issues rather than continually repairing the same faults.

Industrial Fault Finding Services

We provide structured, methodical fault diagnosis and resolution across a wide range of automation systems.

PLC Fault Finding & Troubleshooting

PLC fault diagnostics and error analysis
Debugging control logic issues
Communication fault identification
Rapid resolution of system failures

Control Panel Fault Finding

Electrical fault diagnosis and testing
Wiring and component failure identification
Control Panel layout and design-related fault issues
System tracing and verification

SCADA & HMI Troubleshooting

SCADA communication faults
HMI interface and control issues
Alarm and data system problems
Performance and visibility issues

Emergency & Ongoing Support

On-site fault finding
Remote diagnostics and support
Fast response for critical breakdowns

Improving Fault Finding Through Better Documentation

Well-maintained documentation is one of the most effective ways to reduce fault finding time. Outdated electrical drawings, inconsistent PLC code and missing software backups often mean engineers spend more time locating faults than fixing them.

Our engineers can update electrical schematics, PLC software, I/O schedules and system documentation as part of our EPLAN Control Panel Design service. Accurate records help maintenance teams diagnose faults more quickly, simplify future upgrades and reduce reliance on external support.

Reduce Downtime with Structured Fault Diagnosis

Unresolved automation faults can lead to:

Production stoppages
Lost revenue
Increased maintenance costs

Our structured approach helps you to:

Identify root causes quickly
Restore system functionality efficiently
Eliminate recurring faults
Improve long-term reliability

We do not just fix symptoms, we solve the underlying problem.

Unplanned Downtime for Manufacturing.webp

Maintenance & System Support

Beyond urgent fault finding, we provide ongoing support to improve reliability and reduce the risk of future failures

Preventative Maintenance

System inspections and health checks
Early identification of potential failures
Reduced risk of unexpected downtime

System Optimisation

Improve PLC performance
Optimise control logic and processes
Increase system efficiency

Legacy System Support

Support for older PLC and automation systems
Fault diagnosis on obsolete equipment
Control Panel Refurbishment and Upgrade planning and recommendations
Replace Obsolete Systems

Emergency Fault Finding and Planned Maintenance

When an automation system fails unexpectedly, a rapid response is essential to restore production and minimise downtime. Our engineers provide emergency automation fault finding to identify the root cause of the problem, implement effective repairs and safely return your equipment to operation.

However, the most effective approach is to prevent faults before they disrupt your business. Alongside emergency support, Stratos offers planned maintenance, condition assessments and automation health checks to identify ageing components, recurring issues and opportunities to improve system reliability.

Regular assessments of PLCs, industrial control panels, SCADA systems and associated equipment help reduce unplanned breakdowns, extend the life of your automation assets and support more predictable maintenance planning. Where recurring issues are identified, we can recommend targeted improvements, control system upgrades or control panel refurbishment to improve long-term performance and reliability.

Preventing Future Automation Failures

Resolving today's fault is only part of the solution. We also help organisations improve long-term automation reliability through preventative maintenance, structured diagnostics and system optimisation.

This may include:

improving alarm management
standardising PLC programming
upgrading obsolete hardware
improving SCADA visibility
updating control panel documentation
replacing unreliable components

Our goal is to reduce repeat failures while making your automation systems easier to maintain and support.

Automation Systems We Commonly Diagnose

Our engineers have experience diagnosing faults across a wide range of industrial automation systems, helping organisations quickly identify problems and restore reliable operation.

We regularly investigate faults involving:

PLC systems and machine control software
SCADA and HMI systems
Variable speed drives (VSDs)
Industrial control panels and electrical control systems
Machine control systems
Building Management Systems (BMS)
Industrial communication networks
Remote I/O systems
Safety systems and safety PLCs
Control panel communications and field devices

Whether the issue is caused by hardware failure, software faults, communication problems or ageing equipment, we take a structured approach to diagnosis, testing and resolution. Our goal is not only to fix the immediate fault but also to identify opportunities to improve reliability, update documentation and reduce the risk of future failures.

Systems We Support

We provide support across a wide range of automation systems, including:

PLC systems
Control panels and MCCs
EPLAN Control Panel Design
SCADA and HMI systems
Industrial communication networks
Machine control systems

Industries We Support

Our control panels are used across a wide range of industrial sectors, including:

And industry we support food and beverage industrial automation

Why Choose Stratos Control Systems

Fast response to minimise downtime
Experienced industrial automation engineers
Structured, logical fault diagnosis
Clear solutions and documentation
Long-term reliability improvements

Our control panel designers can help standardise existing systems to improve maintenance efficiency and reduce downtime.

Frequently Asked Questions

Need Urgent Fault Finding Support?

If your system is down or underperforming, Stratos Control Systems can help restore it quickly and reliably.