过程行业是一个高度资产密集型行业，ARC相信过程自动化可以为加工厂带来极高的未实现资产回报率（ROA）。然而，大多数用户购买过程自动化系统是用于保持技术，并降低总拥有成本（TCO）和风险，而不是为了实现持续改进及相关经济收益。ARC还认为面向项目的自动化往往掩盖了过程自动化为ROA做出的真正贡献。这是因为在收益实现之前项目就结束了，整个项目的ROA无法识别过程自动化实现的收益。缺乏一个投资回报率反馈机制和衡量绩效的基本标准使得这一问题更加复杂。
为了提高系统的可靠性，必须考虑输入门槛电平的大小。门槛电平越高，抗干扰能力越强，传输距离也越远，具体可参阅PLC说明书。
这些故障，都可以用合适的故障诊断方法进行分析和用软件进行实时监测，对故障进行预报和处理。
(1)继电器控制装置采用硬逻辑并行运行的方式，即如果这个继电器的线圈通电或断电，该继电器所有的触点（包括其常开或常闭触点）在继电器控制线路的哪个位置上都会立即同时动作。
如果进行了全部的检查之后，［EPROR］LED的灯亮状态仍不能解除，，应考虑PLC内部发生了某种故障，请与厂商联系。
控制系统主要由输入部分、CPU、采样部分、输出控制和通讯部分组成，如图1所示。输入部分包括控制面板和输入模板；采样部分包括采样控制模板、AD转换模板和传感器；CPU作为系统的核心，完成接收数据，处理数据，输出控制信号；输出部分有的系统用到DA模板，将输出信号转换为模拟量信号，经过功放驱动执行器；大多数系统直接将输出信号给输出模板，由输出模板驱动执行器工作；通讯部分由通讯模板和上位机组成。因为PLC本身的故障可能性极小，系统的故障主要来自的元部件，所以它的故障可分为如下几种：
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