PLC Troubleshooting Emergency Call Out: Restoring MicroLogix 1100 , Red Lion HMI, & Red Lion DLC Communication.

📅 Date: September 2–3, 2025

📍 Service Area: Fort Mill, SC

🛠 Equipment: Allen‑Bradley MicroLogix 1100 PLC, Red Lion HMI, Red Lion DLC Module

Emergency Call: Packaging Machine Temperature Controls Down

On Tuesday, September 2, 2025, Carolina Controls NC LLC received an urgent call from a local manufacturer. Their packaging machine temperature controls had stopped responding on the Red Lion HMI.

With heating circuits offline, the client faced costly downtime. We scheduled an onsite PLC troubleshooting visit for the very next day to get them back in operation.

Onsite PLC & HMI Diagnostics

Upon arrival, we worked closely with the facility’s maintenance team to review the symptoms and recent machine behavior. Our process included:

• Uploading the PLC program from the Allen‑Bradley MicroLogix 1100

• Pulling configuration data from the Red Lion HMI and DLC module

• Tracing control logic for the two heating circuits

• Testing communication pathways between devices

Root Cause: Damaged PLC–DLC Communication Cable

Our diagnostics revealed a damaged communication cable between the MicroLogix 1100 PLC and the Red Lion DLC module. This DLC was responsible for controlling both heating zones, so the failure effectively disabled all temperature control functions.

By pinpointing the exact fault, we helped the client avoid unnecessary part replacements and reduced the risk of future downtime.

Why This Matters for Manufacturers

This case highlights the importance of cross‑platform automation troubleshooting. At Carolina Controls NC LLC, we specialize in:

• PLC troubleshooting (Allen‑Bradley, Siemens, Omron, Automation Direct, and more)

• HMI troubleshooting (including Red Lion Controls HMI troubleshooting and programming)

• Industrial communication diagnostics (Ethernet, serial, and proprietary protocols)

• Heating circuit control optimization for extrusion and packaging equipment

Our rapid onsite support across the Southeast keeps production lines running and downtime costs low.

Need Expert PLC & HMI Support?

If your packaging machine, extruder, or automation system is down, you need a partner who can respond fast and solve problems across multiple platforms.

📞 Call Carolina Controls NC LLC — Your trusted local partner for PLC troubleshooting, HMI troubleshooting, and industrial automation support.