Diagnostics, Repairs and Monitoring of Industrial Networks

Stable manufacturing starts with stable communication

Industrial communication networks connect PLCs, distributed inputs and outputs, variable frequency drives, robots, operator panels, sensors and other production equipment. Even a small fault in a cable, connector, termination, switch or network device can gradually cause alarms, slower communication, intermittent outages and ultimately a complete production stoppage.

Many problems remain invisible for a long time. The network may still be operating, while its safety margin is gradually decreasing. Preventive diagnostics helps identify a deteriorating condition before the fault causes production-line downtime.

We do more than measure – we look for the cause and the solution

The purpose of diagnostics is not merely to generate graphs and measured values. The technician combines data from the analyzers with the actual topology, PLC configuration, condition of individual devices and the way the problem appears during production.

When the fault is clearly identified during the visit and can be removed safely, the technician will repair it directly on site following agreement with the customer. Otherwise, you receive specific recommendations describing what should be changed, repaired or modernized.

Diagnostic programs matched to the scope of the problem

BASIC is a quick network check and on-site consultation. It is suitable for an initial preventive measurement, checking a smaller network or obtaining a basic assessment of its condition.

FOCUS is targeted diagnostics of a specific problem, such as intermittent communication outages, an unstable station or one part of a production line.

STANDARD is a more comprehensive analysis of the entire industrial network, including communication, physical layer, topology and associated configuration.

PREVENT is a preventive check performed during a planned shutdown, before acceptance of a new machine or before equipment is placed back into operation.

EXPRESS is a priority intervention following a production failure or critical communication outage. The scope and timing of the visit depend on technician availability and the intervention location.

Monitoring 24/7 continuously monitors the condition of a critical network and provides warnings about emerging faults, unstable devices and gradual deterioration of communication.

PROFINET network diagnostics

During PROFINET diagnostics, we inspect the actual topology, station availability and diagnostic data, alarms, faulty telegrams, network load, communication losses, cable quality, connectors and the condition of industrial switches.

Depending on the available equipment, we work with data from the PLC, network components, passive TAP adapters, cable testers and communication analyzers. The results help identify problems such as damaged cables, faulty connectors, problematic switch ports, overloaded communication or unstable devices.

PROFIBUS network diagnostics

During PROFIBUS diagnostics, we measure the signal quality of individual stations, telegram waveform, voltage levels, reflections, interference, segment termination, the number of repeated telegrams and communication errors.

We also inspect the cabling, connectors, terminators, spur lines, repeaters and division of the network into segments. For older PROFIBUS networks, regular measurement helps extend the infrastructure’s service life and supports the preparation of a gradual modernization plan.

CAN, CANopen, DeviceNet and AS-Interface

For CAN, CANopen and DeviceNet networks, we inspect the physical layer, signal quality, termination, interference, bus load, error frames and communication between individual nodes.

For AS-i networks, we check the power supply and communication of slave devices, cabling condition, interference, addressing and master error messages. When the problem is caused by a faulty component or installation, we propose an appropriate repair.

Industrial Ethernet, EtherNet/IP, EtherCAT and Wi-Fi

For Industrial Ethernet, we check topology, port status, error counters, communication load, broadcast and multicast traffic, packet loss, link speed, duplex settings, network loops and unstable devices.

EtherNet/IP diagnostics may also include inspection of communication between PLCs, distributed I/O, drives and other devices from Rockwell Automation and other manufacturers.

During Wi-Fi diagnostics, we measure coverage, signal strength and quality, interference, channel utilization, roaming stability, speed and wireless-network behaviour under actual operating load.

What will you receive after the diagnostics?

• an overview of the measurements and diagnostic methods used
• a list of identified problems and risk areas
• measured values, signals and diagnostic events
• an overview of devices or stations in the measured network
• network topology, where it can be obtained using the selected methods
• information about faults removed during the intervention
• recommendations for repairing, modifying or modernizing the network
• a proposal for preventive maintenance or long-term monitoring

A service report is included with every one-time measurement. For larger or more complex problems, a detailed technical report can be prepared with an analysis of the causes and a proposal for specific corrective measures.

Fourteen-day monitoring of intermittent outages

Some faults occur only a few times per week, during a shift change, when a particular machine starts or when production load is high. A one-time measurement may therefore fail to capture the exact moment when the problem occurs.

In this situation, we install a monitoring device in the network to supervise communication continuously for 14 days. The technician evaluates the data remotely and, when monitoring is completed, prepares a report with recommendations for the next steps.

You can select PROFINET network monitoring or PROFIBUS network monitoring.

Permanent monitoring of critical PROFINET networks

For key production lines operating continuously, we also offer our proprietary PROFINET Monitoring Centre 24/7. It brings the status of all monitored networks across the factory into one central system and displays stations, alarms, events and trends in monitored values.

The maintenance team can therefore intervene before a complete communication failure occurs. When intermittent problems arise, the stored event history helps determine when and under what conditions the fault occurred.

24/7 technical emergency service for industrial networks

When a critical network failure occurs outside normal business hours, at night or during a weekend, a FOXON technician is available by phone. They will assess the situation with you, recommend the first steps and, depending on the severity of the problem and technician availability, arrange an on-site visit.

24/7 technical emergency service: +420 488 588 749

Prevention, repairs and modernization from one supplier

FOXON provides not only diagnostic services, but also analyzers, cable testers, permanent measuring points, TAP adapters, industrial switches, repeaters, connectors and other components for repairing and modernizing industrial networks.

Our own technicians use the same diagnostic instruments that we supply to customers. This allows us to recommend solutions based on genuine experience gained at manufacturing plants.

We can also train your technicians in network diagnostics

FOXON Academy provides hands-on courses in which maintenance and automation technicians learn how industrial communication works, how to use diagnostic tools and how to identify the causes of faults systematically.

You can select, for example, PROFINET diagnostics training or PROFIBUS diagnostics training.

Preferential diagnostics with FOXON PLUS

Customers participating in FOXON PLUS may receive preferential prices for diagnostics, preventive maintenance, training or expert consultations, depending on their level of cooperation.

When should preventive diagnostics be ordered?

We recommend preventive measurements before or during a planned shutdown, when accepting new production equipment, after a major repair or network extension and at regular intervals for critical production lines operating continuously.

Can you remove the fault immediately during the measurement?

Yes, when the cause has been clearly identified, the repair can be performed safely and the necessary components or configuration access are available. More complex modifications are described first and we propose a safe implementation procedure.

What should we prepare before the technician arrives?

A description of the problem, the timing and circumstances of the outages, network type, number of devices, available topology, PLC diagnostic buffer, photographs of control cabinets and information about changes made before the problem occurred will all be helpful.

Do you also provide services outside the Czech Republic?

Yes. We provide diagnostic and service interventions in the Czech Republic, Slovakia and, by arrangement, in other European countries.