Industrial Fault Diagnosis Software

Industrial fault diagnosis is the process of working from an observed symptom — a motor that will not start, a conveyor that stalls, a drive that trips — to the underlying cause, in a structured and repeatable way. Wiresight is industrial fault diagnosis software that helps maintenance engineers reach that cause faster, document what they find, and turn one-off repairs into reusable engineering knowledge.

Why fault diagnosis consumes engineering time

On most factory floors, fault-finding knowledge lives in the heads of a few experienced engineers. When they are on holiday, on another line, or have moved on, less experienced colleagues are left to work through faults by trial and error — pulling fuses, swapping sensors, guessing at causes. That is slow, inconsistent, and it extends unplanned downtime far beyond the fault itself.

Wiresight captures the reasoning of your experienced engineers as structured diagnostic procedures, so the whole team follows the same logic instead of each engineer starting from scratch.

How structured fault logic works

Rather than jumping to a likely culprit, Wiresight walks the engineer through an ordered set of checks — confirming or ruling out each cause before moving to the next. Each step states what to check, what the expected result is, and any safety warning that applies. AI-assisted diagnostics generate a tailored sequence for the specific fault and equipment type, drawing on your saved repair templates and history.

What Wiresight can help diagnose

Wiresight supports the equipment types most common in industrial maintenance: PLCs, VFDs, motors, relays, contactors, sensors, HMIs, power supplies, circuit breakers and transformers — as well as custom equipment you define. It covers three broad fault families:

• Electrical fault diagnosis — control circuits, 24 V systems, sensors, motors, contactors, relays, VFDs, safety circuits and interlocks.
• Automation fault diagnosis — PLC inputs and outputs, permissives, HMI alarms, communication faults and VFD/PLC interaction.
• Mechanical fault diagnosis — obstructions, jams, overloads and the electrical–mechanical boundary where many faults hide.

See the dedicated electrical fault finding software and PLC troubleshooting software pages for detail.

A worked example: "Conveyor motor will not start"

A simple structured sequence, from safest and most likely cause outward:

1. 1Emergency stop — is the E-stop pulled, latched or faulty?
2. 2Safety circuit — are safety relays healthy and reset?
3. 3Guard / interlock — is a guard open or an interlock failed?
4. 4PLC permissive — does the PLC actually command the motor to run?
5. 5PLC output — is the physical output present and healthy?
6. 6VFD — is the drive healthy, enabled and free of active faults?
7. 7Contactor — does the contactor pull in and carry voltage?
8. 8Motor — is the motor itself healthy and receiving supply?
9. 9Mechanical obstruction — is the load jammed or seized?

The exact sequence is configurable to your machinery and site procedures. Wiresight lets your team build and reuse these procedures as maintenance troubleshooting templates, and the AI maintenance assistant can generate a starting sequence for a new fault.

Complementary to your CMMS

Wiresight is not a replacement for your CMMS. It adds the structured diagnostic layer many CMMS systems lack — sitting alongside your existing work-order and asset records. Learn more on the CMMS integration page.