BooleX finds why your line stopped in minutes, from your own drawings, PLC code and alarm history, whatever PLC brand you run. Read-only, on a PC inside your plant, and backed by controls engineers who can fix what it finds.
Interlock IL-10 stopped supply pump P-101 and heater HE-101 and held the sequence at step 40. Return-to-tank valve XV-105 lost its open limit switch while still commanded open, and alarm A035 followed 5 s later plc 1.
The valve really moved: return flow FT-102 fell from 24 to 3 m³/h in the same seconds ts 2. In June the same alarm was a loose limit-switch bracket on XV-105, but the valve moved fine then wo 3. The alarm response is to check actuator air and limit switches doc 4.
Advisory. Confirm on site before you reset the interlock.
The pattern points to cavitation on the suction side. Discharge pressure PT-101 fluctuated by 0.42 bar (standard deviation over 10 s) and raised A010 on each of the last three caustic washes, each time with tank level LT-101 below 25% ts 1. It has not tripped: IL-05 needs pressure under 1.0 bar for 5 s plc 2.
WO-2026-0120 found the same pattern caused by a part-blocked suction strainer wo 3. The alarm response is to check the strainer and tank temperature, then reduce pump speed doc 4.
Advisory. Plan the strainer check for the next idle step, before the next caustic wash.
One stoppage, cleared: IL-10 on XV-105 at 02:13, restarted 02:41. 61 alarms, 38 of them in one flood after that trip alm 1.
Needs attention: maintenance bypass BYP_FT102 has been on for 9 h, so return-flow interlock IL-07 is disabled ts 2. Confirm with the shift lead whether it is still needed doc 3.
Drafted from alarm history and trends. Edit before you send.
When a line stops at 2 a.m., the cause is in a rung, a drawing, a manual or a work order someone wrote last year. Finding it takes the time. BooleX.ai puts all of it behind one question.
The interlock logic lives in a PLC project that only the integrator really knows.
Forty alarms land in two seconds. The one that matters is somewhere in the list.
The right page exists. Nobody has time to find it with the line down.
Last year's fix sits in a work order nobody thinks to search.
BooleX gives every shift the answers your best engineer would give, from your own plant data, and keeps getting better with every fault you fix.
The night shift gets the likely cause and where to look, without waiting for the PLC specialist to call back.
Confirmed fixes are recalled the next time the fault appears, long after the person who found it has moved on.
Siemens, Rockwell, Schneider, Omron, Mitsubishi, B&R, Emerson, Beckhoff and Bachmann code, new and legacy, with one licence instead of a copilot per vendor.
4M controls engineers who can fix, upgrade and support what BooleX finds.
BooleX.ai joins sources that never talk to each other, so an engineer gets one answer with the evidence attached.
Each vendor's export is parsed into one common model of tags, blocks, sequences, interlocks and alarms. Answers quote the exact rung, line or sequence step, and the same question gets the same answer whichever brand wrote the code.
BooleX.ai groups consequential alarms, finds the first-out and rebuilds the timeline from alarm journals and historian tags.
| Time | Tag | Event | |
|---|---|---|---|
| 02:13:51.4 | XV105_ZSO | Open limit lost | FIRST OUT |
| 02:13:56.4 | A035 | XV-105 discrepancy | HIGH |
| 02:13:56.5 | IL-10 | P-101, HE-101 stopped | HIGH |
| 02:13:56.6 | +35 | Consequential | GROUPED |
Electrical drawings from EPLAN, AutoCAD Electrical, AutoCAD or any CAD tool, even scanned sheets, go into one index with your P&IDs, manuals and work-order history. When the evidence isn't there, BooleX says so instead of guessing.
CLEAREDCaustic wash held by IL-10 on XV-105. Return flow fell, so not the switch fault of WO-2026-0221.
OPENP-101 pressure fluctuating (A010 ×3). Suction strainer, as in WO-2026-0120.
OPENBYP_FT102 on for 9 h. IL-07 disabled.
Air regulator REG-AIR-01 in stock (1), stores B3-11. Limit switch LSW-IND-01 (10), B3-09.
61 total, 38 from one flood at 02:13.
Workflows run on alarms, stops, work orders and shift ends. Each one gathers the evidence, writes a cited briefing to the team's inbox and leaves the decision to a person. They can read, never write.
| Time | Workflow | Briefing | |
|---|---|---|---|
| 02:14 | Alarm briefing | CIP-100 held: XV-105 feedback lost, IL-10 | NEW |
| 03:40 | Recurring fault | Third XV-105 discrepancy in 30 days | OPEN |
| 05:55 | Shift handover | 2 stops, 1 open action, 1 part used | DRAFT |
BooleX replays validated models of your pumps, valves, tanks and heaters on the recorded data, healthy and with the suspected fault. A cause that matches the measurements moves up; one that doesn't is ruled out. Models are validated on your own plant's healthy runs, and stay off for an equipment class until a benchmark shows they help.
mdl://| Model variant | Score | FT-101 residual | |
|---|---|---|---|
| Route stuck closed | 1.13 | 0.02 m³/h | SUPPORTED |
| Circuit restricted | 2.10 | 2.83 m³/h | NOT SUPPORTED |
| Healthy circuit | 2.60 | 5.21 m³/h | NOT SUPPORTED |
Every sector below has its own demo plant, from a dairy CIP skid to a ship's power management system, so you see BooleX on a fault that looks like yours. We work wherever PLCs run the process and the answer is buried in code, drawings and old work orders.
The CIP has held on the caustic wash three times this month. Why?
Shorter CIP and changeover stops in peak season, without calling the integrator at night.
Leak-test rejects on cell 3 have crept up since June. What changed?
Faster fault-finding in utilities and non-GMP areas; no GMP-validated use. BooleX only reads, so it never changes a qualified system.
Station 40 keeps stopping the line on second shift. What is behind it?
Less downtime against customer call-offs. Machine builders answer service calls from the code they shipped.
Chiller 2 tripped in the last generator test. Will it happen again?
Always-on plant, small on-call teams and strict security. BooleX can run fully air-gapped, even at sea.
Twelve demo plants, one per sector, each with its own PLC code, functional spec, manuals, work orders and spare parts. In a 30-minute demo we pick a past stop from the history of the plant closest to yours, the kind that keeps coming back, and you watch BooleX dig through its alarms, trends, code and work orders to the cause, with every source cited. All plant data is synthetic.
The CIP has held on the caustic wash three times this month. Why?
CIP skid, separator and evaporator · 4 past stops to investigate
See the demo Book this demo →Why has the filler stopped after the last two changeovers?
Bottling line: filler, capper, labeller · 4 past stops to investigate
See the demo Book this demo →Leak-test rejects on cell 3 have crept up since June. What changed?
Weld, leak test and vision cell · 4 past stops to investigate
See the demo Book this demo →Why did the SIP cycle abort on vessel 2?
SIP skid on a non-GMP process-development vessel · 4 past stops to investigate · utilities and non-GMP areas; no GMP-validated use
See the demo Book this demo →Station 40 keeps stopping the line on second shift. What is behind it?
Weld and assembly line · 4 past stops to investigate
See the demo Book this demo →The customer's press keeps throwing A802. What is behind it?
Hydraulic press at a customer site · 4 past stops to investigate
See the demo Book this demo →Line 2 keeps stopping on film breaks, even after the last fix. Why?
Palletiser, stretch wrapper, extruder · 4 past stops to investigate
See the demo Book this demo →Two batches went to hold at the dosing step last week. Why?
Batch reactor with phase logic · 4 past stops to investigate
See the demo Book this demo →The pumping station has faulted on three nights this quarter. Why?
Remote sewage pumping station · 4 past stops to investigate
See the demo Book this demo →Turbine 7 has stopped on pitch faults twice since spring. What is the cause?
Wind turbine pitch and converter · 4 past stops to investigate
See the demo Book this demo →Chiller 2 tripped in the last generator test. Will it happen again?
Power and cooling plant · 4 past stops to investigate
See the demo Book this demo →The PMS shed load on the last voyage. Which generator was the cause?
Ship's generators and switchboard · 4 past stops to investigate
See the demo Book this demo →Send us file exports. We run them through BooleX.ai and send back a cited report. Your engineers can check every finding against its source.
How your alarm system performs against EEMUA 191 and ISA-18.2 benchmarks.
A first map of one PLC project, from any of the supported vendors.
Pick up to five recent stoppages that took too long to diagnose. We show what BooleX would have said about each, before any connection to your plant.
Your recurring stoppages on one line, each traced to a cited cause.
The groundwork for an ISA-18.2 rationalisation, done from your own data.
What it will take to move an ageing controller to a current platform.
Everyone who signs off on plant software gets something they can check.
The night shift gets the likely cause with the rung and drawing reference. Every fix is logged, so a repeat fault takes minutes.
Less unplanned downtime and faster recovery. Senior technicians' know-how stays in the plant when they retire.
One tool across Siemens, Rockwell, Schneider, Omron and the rest, not a copilot per vendor. Legacy code gets documented along the way.
No writes to control, and no cloud unless you choose it. A one-way read path inside your IEC 62443 zones.
No lock-in to one automation vendor's licensing. A named engineer behind every site.
Safe to put next to a running plant. BooleX only reads, runs where you choose, and leaves every decision with your team.
It reads your PLCs and historian and never changes anything on the control system.
It explains what happened and what to check. A person makes every call.
Every answer links to the rung, drawing or work order behind it, so your team can check it in seconds. If it doesn't know, it says so.
Fully air-gapped on a PC inside your network, with a model you approve, or in your own cloud. You decide what leaves the plant.
Everything runs on an edge PC inside your plant, language model included. Nothing leaves the site.
The edge PC stays on site. Only the question and the cited excerpts go to a model you approve, such as your own Azure or AWS account. Every call is logged.
BooleX runs in your own cloud account. A small collector on site sends data out and accepts no connections in.
You see the value at each step before you commit to the next, and you can stop after any of them.
We take a past stop from the history of the demo plant for your sector and trace it to the cause through its alarms, trends, code and work orders. Then bring a stop of your own.
A free or fixed-fee analysis on files you send. No connection to the plant and no IT approval needed.
Fixed price. Edge PC on its own segment, live on both shifts, with time to diagnosis measured against your own faults.
Add lines and sites, with one overview across sites, built-in workflows and legacy code review. Updates, tuning and support included.
Something else? Ask it in the pilot form and an engineer will answer.
No. BooleX only reads. It sits on its own network segment and has no way to change your PLCs, SCADA or historian.
Not unless you choose. By default the language model, the index and the historian all run on the edge PC inside your network. With the hybrid option, only the question, the conversation and the cited excerpts go to a model endpoint you approve, and every call is logged.
Yes. In the hybrid option the edge PC stays on site and uses a language model in your own Azure or AWS account. In the client-cloud option BooleX runs in your cloud account and a small collector on site sends data out over HTTPS, accepting no connections in. If the link drops, the collector buffers and catches up.
No. Where you run Ignition, BooleX.ai reads from its historian instead, and PI, WinCC and FactoryTalk Historian are next. Your IT team approves one read connection.
Each covers its own equipment and licensing. Most plants run several brands, and BooleX reads them all through one code model on hardware you choose. The importers are in early access: confirmed against synthetic exports, awaiting a site export.
4M's controls engineers can fix it, migrate the system or take on a support contract. The software and the people come from the same team.
EPLAN and AutoCAD Electrical exports, AutoCAD DXF and DWG, PDF from any electrical CAD tool, scanned drawings, P&IDs and Visio. BooleX reads device tags, terminals and cross-references, so it can follow a signal from the PLC to the cabinet.
That is the case it was built for. Each vendor's export is parsed into the same code model, so answers behave the same on every line; on the bench this is shown with synthetic Siemens and Rockwell exports of the same logic.
BooleX reads DeltaV, PCS 7 and 800xA exports in early access: confirmed against synthetic exports, awaiting a site export. Live data comes over OPC UA, Modbus, MQTT, BACnet, SNMP, DNP3 and IEC 61850, always with read services only.
A standby edge PC can mirror it and take over within five minutes. Nothing on the plant side changes, because BooleX only reads.
BooleX.ai tells you it has no supporting source. It does not guess. Those gaps become a list of documents worth writing.
They are processed offline, never on a public cloud service, and deleted once we deliver the report unless you ask us to keep them for a pilot. We sign your NDA first if you need one.
One line with recurring trips, its PLC exports, drawings and manuals, access to alarm history, and a few hours a week from a controls engineer.
Named for George Boole, professor at Queen's College Cork and the father of Boolean logic, which every PLC rung still executes. BooleX is built in Ireland by 4M Integrated Control Solutions.
We take a past stop from the demo plant for your sector and dig into it with you, online or at your site. Or send us the history of a stop that keeps coming back and get a free analysis.
Pick a 30-minute slot