PLC Programming & Troubleshooting
Expert PLC programming and fault-finding for Staffordshire manufacturers
When production stops due to PLC faults or program issues, every minute costs money. Industrial Control Services provides rapid response PLC programming, troubleshooting, and modification services across Mitsubishi, Allen Bradley, and Omron platforms. Whether you need emergency fault-finding, program modifications, or support for legacy systems, we deliver practical solutions that get your production running.
PLC Systems We Support
Mitsubishi PLCs
- FX series (FX3U, FX5U)
- Q series PLCs
- iQ-R series
- GX Works2/3 programming
- GX Developer (legacy systems)
Allen Bradley / Rockwell
- CompactLogix & ControlLogix
- MicroLogix series
- RSLogix 500/5000
- Studio 5000 programming
- SLC 500 (legacy support)
Omron PLCs
- CP1 & CJ series
- NX/NJ series
- CX-Programmer
- Sysmac Studio
- CPM & C series (legacy)
Common PLC Problems We Solve
Production line stoppages - Program faults, I/O failures, communication errors causing unexpected shutdowns and lost production time
Legacy system support - Older PLC systems where original programming documentation is lost or programmers no longer available
Process modifications - Adding new sensors, changing cycle times, integrating additional equipment into existing control systems
Program backup & documentation - Uploading existing programs, creating backup copies, documenting undocumented systems before they fail
Alarm troubleshooting - Persistent nuisance alarms, incorrect fault codes, sensor calibration issues affecting reliability
I/O expansion - Running out of inputs or outputs, need to add new devices without replacing entire PLC
Our PLC Services
Emergency Fault-Finding
When your production line stops, we respond fast. We troubleshoot program logic, I/O faults, communication issues, and sensor problems to get you running again. We carry diagnostic tools for all major PLC brands.
Program Modifications
Need to change machine sequences, add new functionality, or adjust timing? We modify existing PLC programs safely, test thoroughly, and document all changes.
Legacy System Support
Still running older PLCs with no documentation? We can upload programs, reverse-engineer logic, create proper documentation, and provide ongoing support for systems others won't touch.
New Program Development
From simple machine controls to complex production line sequencing, we develop structured, well-commented PLC programs following industry best practices.
Safety System Upgrades
Machine safety systems need to meet BS EN ISO 13849 standards. We program safety PLCs, integrate safety relays, and ensure proper risk reduction.
Energy Monitoring Integration
While working on your PLC systems, we can integrate energy monitoring to track production efficiency and identify opportunities for electricity cost reduction.
Typical PLC Projects
- Press line sequencing and timing modifications
- Recipe management systems for batch processes
- Conveyor interlocking and material handling
- Machine safety system upgrades to current standards
- SCADA/HMI integration with existing PLC programs
- Multi-axis motion control coordination
- Legacy PLC replacement and program migration
- Production line energy monitoring integration
Why Manufacturers Choose Us
- Rapid response - We understand production delays cost thousands per hour
- Multi-platform expertise - No need for separate contractors for different PLC brands
- Practical solutions - We fix the problem, not just replace expensive hardware
- Documentation included - You get commented code and system documentation
- Legacy system specialists - We support older equipment others won't touch
- Energy focus - Integration with monitoring systems to track production efficiency
Real-World Example
A Staffordshire press manufacturer had a critical Allen Bradley CompactLogix controlling their main production line. When the PLC developed I/O faults during a night shift, production stopped completely. We arrived on-site within 2 hours, diagnosed failed input cards, implemented temporary I/O remapping to keep production running, and returned the next day with replacement cards. We also uploaded the program (which had no backup) and created proper documentation. Total downtime: 3 hours instead of the 2-3 days it would have taken to source parts without our emergency support.
Get Expert PLC Support
Facing PLC issues that are costing you production time? Contact Industrial Control Services for fast, effective troubleshooting and programming support.