1. Purpose and Field of Application
This manual is used for replacing the programmable logic controller (PLC) battery and performing program backup. The procedure is intended for technical personnel who perform maintenance on industrial automated systems, as well as for production management and reliability engineering. It complies with the requirements of DSTU, EN, ISO and is used in industrial installations in Ukraine.
2. Preventive Measures
Important: Before performing any work, disconnect all electrical power sources, use the lockout/tagout (LOTO) procedure, and maintain appropriate safety measures.
Requirements for personal protective equipment (PPE):
- Protective gloves - Safety goggles - Protective clothing - Protective suit
Warning:
- Electrical hazard may occur when working with PLCs due to improper disconnection of the system. - Use of an incorrect battery may result in loss of program or PLC failure.
3. Required Tools and Materials
| Tool Name | Specification | Quantity |
|---|---|---|
| Torque head | Range: 0.5–100 Nm | 1 |
| Multimeter | With voltage and current testing, liquid: 1000 V | 1 |
| Battery compartment key | Selected for PLC model | 1 |
| Battery for PLC | Selected for PLC model | 1 |
| Thermometer | Range: -20°C to +100°C | 1 |
| Protective equipment | Protective gloves, goggles, suit | 1 |
4. Before Maintenance: Inspection
| Item | Check | Acceptance/Rejection Criteria | Notes |
|---|---|---|---|
| 1 | Perform the lockout/tagout (LOTO) procedure | All electrical power is disconnected, signed off | Do not perform without this |
| 2 | Check the battery status | No cracks, damage | Do not use damaged batteries |
| 3 | Check the PLC temperature | Temperature not higher than 40°C | Perform cooling if required |
| 4 | Check the interface status | Absence of moisture, dust | Use dry dust extraction system |
| 5 | Check the battery height | Compliance with manufacturer standards | Do not use batteries in accordance with the requirements |
5. Step by Step: Procedure for Battery and Backup Storage Replacement
- System Disconnection
Perform the lockout/tagout (LOTO) procedure, disconnect the PLC power supply, check for absence of voltage at the battery terminals. Use a multimeter in the voltage test mode.
Error: Performing work without disconnecting the power supply may cause electrical disturbances.
- Battery compartment opening
Use a key to open the battery compartment. Check that the compartment is open without resistance.
Error: Incorrect valve opening may lead to component damage.
- Removal of the old battery
Remove the old battery using appropriate tools. Check for absence of contact between the battery and other components.
Error: Removal of the battery without appropriate means may cause damage to the contact.
- Preparation of a new battery
Check the new battery against the PLC model. Use a thermometer to check the temperature. The temperature should be within 15–25°C.
Error: Use of the battery not in accordance with the PLC model may result in loss of program.
- Installation of a new battery
Install the new battery in the battery compartment using the appropriate tools. Check that the contacts are clean and undamaged.
Error: Installing the battery without clean contacts may cause incorrect operation.
- Battery Connection
Connect the battery to the PLC. Check that the contacts are properly secured. Use a torque wrench for fixing.
Error: Incorrect battery connection may lead to electrical disturbances.
- Program Backup
Use PLC software to perform program backup. Execute backup to the appropriate data carrier.
Error: Lack of backup storage may lead to loss of program after power off.
- System Restoration
Check the PLC operation after installing the new battery. Use a multimeter to check the voltage and current.
Error: Incorrect system recovery may lead to incorrect operation.
6. After Maintenance: Inspection
| Test | Expected result | Actual Result | Pass/Fail |
|---|---|---|---|
| 1 | The battery works | Power Supply Availability | Pass |
| 2 | The program has been restored | Availability of backup copies | Pass |
| 3 | PLC temperature within the range | Temperature 15–25°C | Pass |
| 4 | Absence of electrical disturbances | Electrical stability availability | Pass |
7. Technical Support: Table of Problems
| Symptom | Causes | Actions |
|---|---|---|
| PLC Failure | Absence of battery | Install battery |
| Program Loss | Absence of backup copying | Perform a backup |
| Incorrect operation | Battery Connection Error | Check connection |
| Low current | The battery does not meet the standards | Replace battery |
8. Recommended Maintenance Schedule
| Task | Frequency | Estimated duration | Skill Level |
|---|---|---|---|
| Battery Replacement | Annual | 1–2 years | Average |
| Backup | Monthly | 15–30 minutes | Low |
| Contact Check | Quarterly | 10–20 minutes | Low |
| Dust cleaning | Monthly | 10–15 minutes | Low |
9. Table of cut-off with particles
| Part description | Typical specification | Category UNITEC-D |
|---|---|---|
| PLC Battery | 24 V, 10 Ah | 12000 |
| Battery compartment key | Selected for PLC model | 13000 |
| Protective equipment | Protective gloves, goggles | 11000 |
| Multimeter | Fluid: 1000 V | 14000 |
| Thermometer | Range: -20°C to +100°C | 15000 |
Для отримання детальної інформації про вироби, відвідайте наш e-каталог на: https://www.unitecd.com/e-catalog/
10. References List
This manual complies with the standards:
- DSTU 4173-2019 - Industrial System Safety Standards
- EN 50081-1 - Electrical System Standards
- ISO 12100 - Industrial Mechanism Safety
- CE and UkrSEPRO certification
It is recommended to use the PLC manufacturer's documentation additionally.
