wendaiyu

After a power outage, Logix5561 lost the program?

6 posts in this topic

Hi, guys, how’s going?

 

Two weeks ago, after a power outage, Logix5561 lost the program, so we had to download the program to the controller.

 

Then we installed a new battery (which we bought 2 years ago). But the same issue still happened after a power flicker yesterday.

 

We checked the battery with multi-meter, it looks like OK, cuz there’s 3.2V on it.

 

Could somebody give us a hand to fix it?

 

Thanks a lot.

Logix5561__1.JPG

Logix5561__2.JPG

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Go on line into the Controller properties to the Minor Faults tab and hit the 'Clear Minors' button.

Also, if you have a new Power Supply like the existing one, swap them out to see if the problem happens again.

Edited by Filthy McNasty

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Get a preventative maintenance schedule setup for PLC processor batteries.  The first power outage was your wake-up call that this subject may not be properly addressed.

1756 ControlLogix batteries are lithium and derated due to their environment temperature.  Panel temp (106-113F) derates typical battery life to 2 years; (97-104F) derates to 3 years (page 38).  http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1756-um001_-en-p.pdf

Get a preventative maintenance schedule setup for replacing your spare batteries.  The battery meters out as awesome until you put a load on it, then it cannot handle the load?

The 1756-BATM external battery module, if the lithium pack is healthy, will provide longer ride-through and reduce the potential for a similar event.  http://literature.rockwellautomation.com/idc/groups/literature/documents/in/1756-in576_-en-p.pdf

It appears that gaps in the PM of the battery and battery storage may be your root-cause, but a faulty rack power supply could pull that reserve ride-through battery down, as Filthy notes.  If you have an old school oscilloscope, meter the bus voltage and battery voltage powered up, powering down, powering up for a few cycles taking notes as you go.

Speaking from experience, too

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Please post which firmware is loaded into the CPU.  We had a similar issue with 5561 processors.  I believe we had version 16 installed.  It did not matter if the battery was new or not.  We could not find the source of the error.    We upgraded to a newer level and (knocking on wood) have not had the issue since.  

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We had a problem on an old Phase I DriveLogix processor where it would lose its memory sometimes when the power was turned off. The electricians would replace the battery every time even though the battery light wasn't on. It turned out that the battery wasn't the issue at all but it was a problem with the hardware that went away when we replaced it for another problem. I can't find the knowledge base article on it. I don't know if the L61 had a similar bug or not.

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When the BAT LED indicator is on solid red, the controller isn't detecting the battery being connected.

That means the connector is damaged, or is connected wrong (that's not an A-B battery), or there's some other damage or defect that's causing the controller to not detect the battery.

But clearing the memory on a power cycle is absolutely normal and expected when the battery is not properly installed and ready to run.

I would start by installing a genuine battery, and if that doesn't work, replace the CPU or set it up so that it loads from the nonvolatile memory CompactFlash card (if your application can tolerate that) after a power cycle.

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