PLC 5/40E losing program - PLCS.net

sparky_28 · August 13th, 2019, 08:51 PM

Have a PLC5/40E that has a battery installed and a working battery warning light that is off with the battery plugged in. There is no memory module installed.

Following a several second power outage the PLC lost its program, I am told by the building maintenance manager this is not the first time that this has happened.

I attached a fault log if anyone knows how to decipher it.

Thanks

Mickey · August 13th, 2019, 08:57 PM

Power surges can cause this. I have installed UPS's to help cure this problem.

Check grounding and surge protection for all inductive loads.

Ken Moore · August 14th, 2019, 04:57 AM

Power surges, brown outs etc.... have wiped programs in the PLC5 and SLC platform at many of my sites. UPS is best solution, even a small one will help you ride out the "bumps".

JesperMP · August 14th, 2019, 05:14 AM

Or install a memory card, and monitor the "memory was loaded" bit (dont remember which one). When the memory was reloaded, trigger an HMI alarm to notify the operator that he may have to check and reenter settings that may have been reset to default values.

But I guess a memory card for a PLC5-40E may be more expensive than a UPS.

geniusintraining · August 14th, 2019, 05:49 AM

Quote:

Originally Posted by Mickey

Power surges can cause this. I have installed UPS's to help cure this problem.

Same here, worked great !

saultgeorge · August 14th, 2019, 06:03 AM

Hi, and welcome to the forum. We had a lot of those PLC 5's out west where I worked, and like JesperMP said, we had EEPROMs in all of them. There were configuration options to "load from EEPROM" when recovering from a power cycle, plus the processors had a good battery. Maybe those EEPROMs are available on Ebay or somewhere. Hope this helps.

geniusintraining · August 14th, 2019, 06:23 AM

Quote:

Originally Posted by saultgeorge

Maybe those EEPROMs are available on Ebay or somewhere..

Here are a couple... and its from a great seller

https://www.ebay.com/itm/371894342265

https://www.ebay.com/itm/282398316348

JesperMP · August 14th, 2019, 06:35 AM

In case you go for the EEPROM:

To select "EEPROM memory transfers to processor memory if processor memory not valid." you have to set both switches 6 and 7 in the chassis backplane to ON.

Then in the PLC code you monitor S:10/3 "EPROM memory transfer at power-up". Use this to trigger the HMI alarm.

sparky_28 · August 14th, 2019, 03:35 PM

There are roughly 40-45 PLC 5's in the facility. The unit that is losing its program is housed in a control panel with another PLC 5. I will double check though that the grounding is good.

I doubt they will go for memory module, but they may be willing to try a UPS.

August 13th, 2019, 08:57 PM	#2
Mickey Lifetime Supporting Member Join Date: May 2003 Location: Palmdale,Ca Posts: 10,241	Power surges can cause this. I have installed UPS's to help cure this problem. Check grounding and surge protection for all inductive loads. __________________ Mickey If you want happiness for an hour-take a nap. If you want happiness for a day-go fishing. If you want happiness for a month-getmarried. If you want happiness for a year-inherit a fortune. If you want happiness for a lifetime-help someone else. ----- Chinese Proverb

August 14th, 2019, 04:57 AM	#3
Ken Moore Lifetime Supporting Member Join Date: May 2004 Location: North, West, South Carolina Posts: 2,621	Power surges, brown outs etc.... have wiped programs in the PLC5 and SLC platform at many of my sites. UPS is best solution, even a small one will help you ride out the "bumps". __________________ https://www.crossco.com/process-controls

August 14th, 2019, 05:14 AM	#4
JesperMP Lifetime Supporting Member + Moderator Join Date: Feb 2003 Location: Copenhagen. Posts: 13,809	Or install a memory card, and monitor the "memory was loaded" bit (dont remember which one). When the memory was reloaded, trigger an HMI alarm to notify the operator that he may have to check and reenter settings that may have been reset to default values. But I guess a memory card for a PLC5-40E may be more expensive than a UPS. __________________ Jesper See my profile interests for Q&A

August 14th, 2019, 06:03 AM	#6
saultgeorge Lifetime Supporting Member Join Date: Jul 2015 Location: Detroit Posts: 216	Hi, and welcome to the forum. We had a lot of those PLC 5's out west where I worked, and like JesperMP said, we had EEPROMs in all of them. There were configuration options to "load from EEPROM" when recovering from a power cycle, plus the processors had a good battery. Maybe those EEPROMs are available on Ebay or somewhere. Hope this helps. __________________ Detroit City Limit: An Automation Alley Community

August 14th, 2019, 06:35 AM	#8
JesperMP Lifetime Supporting Member + Moderator Join Date: Feb 2003 Location: Copenhagen. Posts: 13,809	In case you go for the EEPROM: To select "EEPROM memory transfers to processor memory if processor memory not valid." you have to set both switches 6 and 7 in the chassis backplane to ON. Then in the PLC code you monitor S:10/3 "EPROM memory transfer at power-up". Use this to trigger the HMI alarm. __________________ Jesper See my profile interests for Q&A



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August 14th, 2019, 03:35 PM	#9
sparky_28 Member Join Date: Aug 2019 Location: Ohio Posts: 2	There are roughly 40-45 PLC 5's in the facility. The unit that is losing its program is housed in a control panel with another PLC 5. I will double check though that the grounding is good. I doubt they will go for memory module, but they may be willing to try a UPS.

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