Overcoming Hardware-Induced False Alarms in Critical Infrastructure

Reliable systems are not built by assuming correctness; they are built by designing for uncertainty. In real-world environments, this means going beyond surface-level integration and developing a deep understanding of how systems behave under all conditions. It requires visibility into low-level system behavior, where signals originate and change, as well as explicit control over how those signals are interpreted. It also means maintaining the ability to override or gate automated actions when necessary, ensuring systems do not react blindly to ambiguous or unintended inputs

However, hardware does not operate purely in steady-state conditions. During events like reboot, failover, or power loss, systems can enter transient states , brief electrical behaviors that don’t represent intentional commands but can still be interpreted as such.

These edge conditions are often overlooked in system design. And when they are, the result is a class of problems that is both common and difficult to diagnose:

False triggers are caused not by failure, but by misinterpreted hardware behavior.

When “Valid Signals” Aren’t Valid

In many systems, signal interpretation is binary:

High = action

Low = no action

This works under stable conditions. It breaks down during transitions. During reboot or power cycling, hardware can:

Briefly drive outputs high

Float between voltage states

Transition through intermediate values

From an electrical perspective, this is normal behavior. From a system perspective, it can be catastrophic. Because downstream systems do not distinguish between intentional signals or transient states. They simply react. As Sarayu Rayabharapur explained:

“The integration logic assumed stable signal behavior, but the hardware introduced transient voltage states that mimicked valid control signals.”

A Real-World Example: When Reboot Triggers Shutdown

This issue surfaced in a deployment involving a gateway and a set of repeaters in a critical communications environment.

During normal operation:

Low (0V) = normal state

High (~-3.5V) = shutdown command

During reboot, the gateway output briefly transitioned to a high signal before returning to normal. That signal lasted only a few seconds, but it was enough. The repeater interpreted it as a legitimate shutdown command and powered down, without any actual failure or operator input.

This wasn’t a bug. It wasn’t a misconfiguration. It was a perfectly valid electrical signal occurring at the wrong time.

Why These Issues Are So Common

This type of issue is not rare. It’s systemic. As noted in the engineering analysis:

“Transient states during reboot or power loss are often overlooked because systems are typically designed and tested under steady-state conditions.”

Most systems are validated under stable conditions. Testing typically assumes consistent power, normal operation, and expected workflows, where inputs and outputs behave predictably. Under these circumstances, systems perform as designed, reinforcing the assumption that signal behavior will remain consistent across all operating states.

However, these same systems are rarely tested under transitional conditions such as reboot cycles and power fluctuations. These moments introduce brief but significant variations in electrical behavior that fall outside normal operating assumptions. Because they are short-lived and difficult to capture, they are often overlooked during validation.

As a result, transient states go unaccounted for. Integration logic continues to assume stability, interpreting any signal it receives as intentional. When edge conditions occur, these assumptions break down, and systems can respond to unintended inputs, creating outcomes that appear unpredictable, but are in fact a direct result of untested conditions.

Why Traditional Debugging Falls Short

These issues are also difficult to diagnose. They often:

Don’t appear in logs

Occur during system transitions

Last only milliseconds to seconds

In this case, there were no logs during the reboot window. Timestamps were unreliable. The issue had to be identified through correlation and physical measurement. Voltage testing revealed:

A temporary high signal during reboot

Floating voltages during power removal

The key insight wasn’t in the logs; it was in the timing. As Sarayu Rayabharapu puts it:

“Logs don’t tell you everything. Timing does. Once you focus on when it happens and map everything around it, the real issue usually reveals itself.”

Designing for Reality: Not Assumptions

The resolution in this case was not to “fix” the signal, but to remove ambiguity from the system.

Automatic reboot was disabled

A manual key switch protocol was introduced

State transitions were made explicit and controlled

This reflects a broader design principle: You cannot always control hardware behavior, but you can control how your system responds to it.

Rethinking Failover and Control Systems

This issue also exposed a deeper challenge in failover design. Many failover systems are built to trigger automatically based on predefined signal thresholds and then persist in that state until a reset condition is met. This approach assumes that once a failure is detected, the system can safely remain in a failover state until normal conditions are restored.

In practice, however, this assumption does not always hold. Without explicit reset mechanisms, systems can remain in unintended states, especially when signals are ambiguous or influenced by transient conditions. In some cases, recovery signals may be misinterpreted or never properly registered, leaving the system effectively stuck. What was intended to be an automated recovery process ultimately requires manual intervention to restore normal operation.

The lesson is that failover design cannot focus solely on triggering a response. It must also account for how systems return to a stable state. Failover is not just about detecting failure; it is about ensuring controlled, reliable recovery.

Lessons for Integrators

For engineers and integrators, this case highlights a set of critical considerations:

Reboots are not neutral events

Hardware signals are not always stable during transitions

Transient states must be treated as real inputs

Logs are not sufficient for diagnosing edge conditions

Signal validation must include timing, not just value

Most importantly: If your system reacts to signals, you must understand how those signals behave under all conditions, not just normal ones.

Designing for Edge Conditions

The behavior observed in this scenario highlights a fundamental gap in many integration designs: systems are typically validated under steady-state conditions rather than during transitions.

Reboot cycles, voltage fluctuations, and failover events introduce intermediate states that fall outside normal operating assumptions. When these states are not explicitly accounted for, systems may respond to valid signals arising from unintended circumstances.

Engineering for reliability requires treating these edge conditions as first-class scenarios. Signal timing, persistence, and transition behavior must be considered alongside value. Without this, even well-designed systems can produce unpredictable outcomes

Modern integration approaches reflect this shift in thinking. Rather than relying solely on fixed logic and assumptions, they move toward software-defined control layers that allow for greater flexibility and oversight. Deterministic workflows ensure that actions are predictable and repeatable, while explicit state management clarifies how systems transition between conditions.

Ultimately, integration is not just about connecting systems. It is about ensuring they behave predictably and reliably, especially when conditions fall outside the norm.

Talk to Teldio About Reliable System Design

Designing resilient systems requires more than integration; it requires understanding how systems behave under real-world conditions.

Contact Teldio to learn more about our approach to system reliability and integration at scale.