PROCESS CONTROL SYSTEM WITH IMPROVED FAULT ISOLATION

A process control system includes redundant digital controllers and a plurality of input/output (I/O) modules for interfacing with remote field sensors and actuators. Bi-directional communication between controllers and I/O modules is achieved by a parallel-wired, process I/O bus. Failures within the system, including the bus structure itself, that continually keep the bus active (i.e., in a low state) are isolated by a combination of software diagnostic routines for performing bus checkout and a unique quick disconnect feature that readily isolates the fault condition first between the I/O module nest area and the controllers, then, if necessary, to individual I/O modules. During fault isolation procedures, individual I/O modules may be disconnected from the bus while the values of field signals are simultaneously maintained to provide minimum process upset.