3 problems caused by damaged PLCs and how to avoid them

Processor damage in PLCs is a big challenge in the routine of any automated operation. When this happens, the device becomes unusable and makes it impossible to continue the processes it was controlling. Fortunately, there are simple and inexpensive ways to prevent this loss.

Understand 3 problems caused by PLC damage

1. The cost of a new device

Losing equipment makes it necessary to replace it. This generates an acquisition cost for this new device. It is difficult to find a PLC of the same model in stock for immediate replacement and, even if there is, it is necessary to account for the replacement time.

When there is no equipment to replace the damaged PLC, you must purchase a new one and wait for the delivery time, in addition, of course, to the installation time already mentioned. If the product is imported, chances are that the wait for a new part will be weeks, producing all kinds of delays in the programming of operations.

2. Production downtime

Production downtime due to a damaged PLC is a more common problem than you might think, and yet there are companies that know simple and inexpensive solutions to avoid this type of problem. The downtime generates extra costs, besides the need to purchase new equipment. Unproductive time is directly linked to negative revenue.

Production downtime also requires the responsible teams to stop their planned activities to solve a problem that could be avoided.

3. Downtime and its consequences

The losses of downtime go beyond financial and time resources. Downtime has a negative effect on individual employee productivity, as their attention is diverted, and it takes time to regain pace and concentration before the unforeseen event.

Manufacturing operation deliveries are also compromised with downtime, generating negative impact for customers, who risk receiving their orders late.

How to avoid burning out your PLC

The interface relay is a low-cost device that provides security and allows you to continue your operations.

An outstanding element in NOVUS product portfolio, the NIO interface relay is designed to fulfill the offer of electronic devices and equipment, offering the confidence and quality of the brand. This product is available now. Its main benefit is to protect inputs and outputs. This prevents the electrical burning of devices in case of power surges.

Besides providing protection so that more sophisticated and expensive equipment doesn’t get damaged, the cost-effectiveness of an interface relay like NIO also brings advantages such as:

  • Fast relay replacement
  • Avoids plant downtime
  • Three power models, suitable for the different demands of the installed equipment.

See the technical specifications of the NIO interface relay and request a quote.


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Learn more about interface relay

What is an interface relay?

An interface relay such as NIO works as an electrical switch that is responsible for opening and closing an electronic or electromechanical circuit. This serves to maintain electrical isolation between the circuit and the control.

The interface relay is widely used in the isolation of control systems (at the inputs or outputs), to protect equipment against voltage surges and short circuits.

This type of device for automation is an assembly consisting of a DIN rail socket base and a replaceable coupling relay that opens and closes the circuit, ensuring electrical isolation between the control and the circuit.

In case of overload, the coupling relay is easily replaced since the overload will burn this simple and inexpensive device and protect the other equipment in the system.

Also known as auxiliary relay, safety relay, or isolator, the NIO controls the electrical circuits through NO (normally open) or NC (normally closed) contacts.


What is the purpose of the interface relay?

An interface relay such as NIO provides electrical isolation, avoiding the burning of equipment in cases of power surge or short circuit. In panels and industrial automation systems, the main purpose of an interface relay is to separate the load drives from the command. This way, the coupling relay maintains the integrity of equipment and systems, such as controllers and PLCs.