Downtime is costly in any industrial setting, and when a programmable logic controller (PLC) fails, production can grind to a halt. The good news is that many PLC issues are repairable, and when handled quickly, repairs can get systems back online without the need for expensive replacements.
At ACS Industrial, we see a wide range of PLC problems every day, and many of them can be resolved faster than you might expect.
Common Repairable PLC Failures
One of the most frequent failures we encounter involves power supplies. PLCs depend on stable power to operate correctly, and when a power supply fails, the entire controller can shut down. Symptoms might include random resets, failure to boot, or complete loss of communication with the system. Replacing or repairing the power supply is often enough to bring the PLC back into full operation.
Another typical point of failure is input/output (I/O) cards. These cards are the interface between the PLC and the machinery it controls. If an input card fails, the controller may no longer detect signals from sensors. If an output card fails, it may stop sending commands to actuators, motors, or valves. Because these cards are modular, repairing or replacing them is a targeted fix that can restore production quickly without the need to service the entire PLC.
Batteries are another simple but critical component. Many PLCs use onboard batteries to maintain memory and store programs when power is lost. A dead battery can lead to wiped programs or corrupted data, leaving the machine unable to run until the program is restored. Replacing a battery is a fast repair, but it can save hours of downtime if handled promptly.
Why Repairs Often Beat Replacements
When production stops, the instinct may be to replace the PLC entirely. While this sometimes makes sense for older or heavily damaged units, repairs are often faster and more cost-effective.
New hardware may not be immediately available, especially if the model is discontinued or has long lead times. Repairs, on the other hand, can often be completed in days, and in many cases, a repaired PLC performs as reliably as a new one.
In addition, repairs allow you to keep your existing system in place. There’s no need to reprogram a new controller, rewire hardware, or retrain staff on updated equipment. By repairing common failures like power supplies, I/O cards, and batteries, you can minimize disruption and get your lines running again with minimal delays.
Getting Back to Production Fast
At ACS Industrial, we specialize in diagnosing and repairing PLC failures that stop production in its tracks. Whether it’s a simple battery replacement or a more involved repair of power supplies and I/O modules, our team works quickly to restore your equipment to working order.
When your PLC goes down, it doesn’t always mean a costly replacement or extended downtime. In many cases, targeted repairs are all that’s needed to get you running again. If your system is offline, ACS Industrial is here to help you restore production as fast as possible.
Call ACS Industrial for Repairs and Service for Your PLCs!
Knowing how to keep programmable logic controllers and other industrial electronics in operation can be tough, but you don’t have to do it alone. At ACS Industrial Services, we specialize in preventative maintenance and repair services for industrial electronic equipment.
With over 20 years of experience, ACS is a leading industrial repair service provider when things break. We repair many different components of machinery across various makes and models. We provide a rapid turnaround time. Most repairs are back in your hands within 7-15 business days, with our Rush Repair Service typically shipping in just 3-5 business days.
Contact us for a FREE evaluation and a no-obligation quote, or call (800) 605-6419.