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Start Your New Year Off Right with Our Checklist

January 1, 2016
Did you know that with regular routine maintenance, you can increase the lifespan of your PLC? Many malfunctions happen as the result of problems that have been building up for some time, such as an environment with lots of dust and debris or a connection that’s been under par for a while. With regular maintenance of your PLC, you can prevent problems and make your PLC last longer. What’s a better New Year’s Resolution than that? Start your New Year off right with our checklist for superb PLC maintenance!


You’ve numerous things to check when it comes to your PLC. Our list includes checking:
  • LED Indicators. Ensure the power and battery LED indicators are on. If they’re flickering, this could be a sign that your battery is about to expire or you’re having problems with the power source.
  • The environment. Your PLC’s environment should be operating in the right conditions. This means proper airflow, clean filters, good temperature, and proper humidity.
  • Operating voltage. It’s crucial that the input voltage is within the appropriate range and free from power spikes.
  • Program functionality. Check to ensure the unit is operating as intended.
  • Ensure all connections are properly connected. This includes cables, plugs, and sockets. You may want to perform this check more often than the others, especially if your PLC’s environment is subjected to vibrations.


There are certain replacement steps you should take when performing PLC maintenance:
  • Replace battery. You’ll need to check the battery status and replace if necessary. If the battery light is flickering or on, it’s time to change the battery.
  • Replace parts. You’ll need to identify updates and replacement parts as needed. Some upgrades may be necessary. Conduct an audit to ensure each component of your PLC is working as intended and replace anything that isn’t.
  • Have replacement parts. Having replacement parts in stock is important because, when a component of your PLC fails, it affects your entire system. Keep some replacement parts in stock and keep your PLC’s downtime to a minimum in situations like this.


Ensuring your PLC is working great and in the best environment involves inspecting certain things, such as:
  • Overheated parts. Any warping or discolored cases could mean overheating of the CPU and other modules.
  • For cleanliness. Clean to ensure no dust and dirt are penetrating the PLC’s parts. There should be adequate airflow and a clean space to ensure overheating or failure from dust and debris does not occur.
  • For unnecessary items. Items that are not a part of the PLC should not be on or around the PLC such as manuals and other materials. This can inhibit proper airflow, therefore leading to a problem. Clear the space!
Always remember to back up your PLC’s program as well. Saving a copy during your maintenance can help you get the information you need back onto your PLC in the event that it fails or a replacement is needed. PLC maintenance can prevent problems and keep all components of your PLC running smoothly. Start your New Year off right with our checklist—quarterly inspections of your PLC and its components can save you time and money in the new year!  
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