Electronics & Communication Failures
Electronics and communication issues are often misdiagnosed as analyzer faults. In reality, many failures originate from power quality, grounding, cabling, or configuration — not from defective analyzer hardware.
Field rule:
If multiple analyzers show intermittent issues,
suspect utilities and grounding before electronics.
Typical Symptoms
- Intermittent analyzer trips or resets
- Frozen values on DCS / SCADA
- Loss of communication alarms
- Random I/O errors or checksum faults
- Analyzer works locally but not remotely
Common Root Causes
- Unstable or noisy power supply
- Improper earthing or multiple ground points
- Loose or corroded terminals
- Incorrect communication settings
- Electromagnetic interference (EMI)
- Aging or failing power supplies
Frequent Failure Modes
- Power dips: cause analyzer reboots or logic faults
- Ground loops: introduce noise into signals
- Loose connections: create intermittent faults
- EMI pickup: corrupts communication data
- Configuration mismatch: causes DCS misinterpretation
Correct Troubleshooting Order
1) Verify power quality and voltage stability
2) Check earthing continuity and single-point grounding
3) Inspect terminals, connectors, and cable glands
4) Validate communication parameters end-to-end
5) Review error logs and event history
6) Replace electronics only after external causes are ruled out
Common Design & Installation Mistakes
- No UPS or power conditioning
- Shared grounding with high-power equipment
- Signal cables routed near power cables
- No strain relief on terminal connections
- Lack of EMI shielding in analyzer shelters
Best Practices
- Provide clean, conditioned power to analyzers
- Implement proper single-point grounding
- Use shielded cables and correct termination
- Document all communication settings
- Trend communication health parameters