What are the risks of using a low-quality PLC backup battery?

A programmable logic controller (PLC) is a device that controls industrial processes and machines by executing a set of instructions. A PLC backup battery is a vital component that preserves the memory and data of the PLC in case of a power outage or failure. However, not all backup batteries are created equal, and using a low-quality one can have serious consequences for your PLC system and your business. In this article, we will discuss some of the risks of using a low-quality PLC backup battery and how to avoid them.

1 Data loss

One of the most obvious risks of using a low-quality PLC backup battery is data loss. Data loss can occur when the backup battery fails to provide enough power to maintain the PLC memory during a power outage or when the backup battery is drained or damaged by external factors. Data loss can affect the PLC program, the configuration settings, the historical data, and the alarms and events. Depending on the complexity and criticality of your PLC system, data loss can result in production downtime, quality issues, safety hazards, and increased costs.

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2 System failure

Another risk of using a low-quality PLC backup battery is system failure. System failure can happen when the backup battery causes a short circuit or a voltage spike that damages the PLC hardware or software. System failure can also occur when the backup battery is incompatible with the PLC model or manufacturer, or when the backup battery is installed incorrectly or without proper precautions. System failure can render your PLC system inoperable, requiring extensive troubleshooting, repair, or replacement.

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3 Compliance issues

A third risk of using a low-quality PLC backup battery is compliance issues. Compliance issues can arise when the backup battery does not meet the standards and regulations of your industry or region, such as UL, CE, or RoHS. Compliance issues can also emerge when the backup battery does not have a proper label, documentation, or warranty. Compliance issues can expose your PLC system to legal liabilities, fines, penalties, or audits.

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4 How to avoid these risks

The best way to avoid these risks is to use a high-quality PLC backup battery that matches your PLC system and your application requirements. A high-quality PLC backup battery should have a long lifespan, a low self-discharge rate, a high temperature tolerance, and a reliable performance. A high-quality PLC backup battery should also have a clear identification, a valid certification, and a reputable supplier. Additionally, you should regularly monitor, test, and replace your PLC backup battery according to the manufacturer's recommendations and best practices.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Brandon Teachman

Helping YOU improve manufacturing through Industrial Automation.
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The easiest way to prevent this issue is to reach out to your authorized PLC distributor. They will see a quality product, to ensure there customers don’t have issues. Purchasing the cheapest one you can find online, often will not have great results.

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What are the risks of using a low-quality PLC backup battery?

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1 Data loss

2 System failure

3 Compliance issues

4 How to avoid these risks

5 Here’s what else to consider

Programmable Logic Controller (PLC)

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