A Modbus TCP timeout between a Triconex Trident safety PLC and a Yokogawa CENTUM VP DCS can trigger nuisance trips costing $50,000+ per hour in refinery applications. This 7-step diagnostic playbook covers TCM LED status, Modbus connection counter analysis, IP configuration validation, Wireshark packet capture, holding register mapping verification, diagnostic register monitoring, and failover behavior testing — plus OPC UA as a complementary diagnostic layer.
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