Learning outcomes
- Explain the key principles of spares, backups and lifecycle management.
- Carry out a structured practical check or configuration task.
- Recognise common faults, risks and evidence needed for diagnosis.
Module 14 · Lesson 4
Spares, backups and lifecycle management
Manage critical spares, firmware, software, licences, obsolescence and tested replacement procedures.
Before you begin
Asset and software inventory.
Safety: Use site procedures, approved test equipment and competent supervision. Never bypass a protection or interlock without formal control.
Step-by-step learning
- Record model, revision, firmware, configuration and installed location.
- Identify critical spares with storage and periodic test requirements.
- Maintain offline backups and installation media.
- Plan migration before hardware or software becomes unsupported.
Ian's practical tips:
- A spare PLC CPU without the correct firmware and project may not be a useful spare.
- Label spares with compatibility and last-test date.
Fault-finding questions
- What should be happening, and what evidence proves it?
- Where is the last known correct signal, voltage, state or process condition?
- What changed immediately before the fault?
- Can the system be divided into smaller testable sections?
Practical activity
Create a one-page test record for this lesson. Include expected values, measured results, equipment used, risks controlled, defects found and the final proven condition.