PLC Technology

7381 Encoder 1 Fault in ABB ACS880 Drive

Fault Code - 7381

Cause

Encoder 1 Feedback Fault

Solution

If fault appears during first start-up before

encoder feedback is used:

- Check cable between encoder and

encoder interface module (FEN-xx) and

order of connector signal wires at both

ends of cable.

If fault appears after encoder feedback

has already been used or during drive :

- Check that encoder connection wiring

or encoder is not damaged.

- Check that encoder interface module

(FEN-xx) connection or module is not

damaged.

- Check earthings (when disturbances

are detected in communication between

encoder interface module and encoder).

For more information on encoders, see

parameter groups 90 Feedback

selection, 91 Encoder module settings,

92 Encoder 1 configuration and 93

Encoder 2 configuration.

Check the event log for an auxiliary code.

See appropriate actions for each code at

warning A7E1 Encoder 1 (page 259).

Manual Download

Logix Data Transfer Utility

This Software for Excel file data Upload and Download to Controllogix or Compactlogix PLC via Ethernet. If your Recipe data stored in PLC. But, you can't take backup to Excel file. This problem solve by Logix Data Transfer Utility Software. You can take machine recipe related data to excel file. User friendly software. No need any PLC related software like Rslinx, OPC server, Rslogix and etc.

PLC data upload to excel file

Open the Logix Data Transfer Utility software
Click Open Button. Then Select the tag list excel file with PLC tag list (.xls)

PLC Tag list
Then enter the PLC IP address and PLC slot number.

Add caption
Click Ping button for checking the PLC ping or not.

IP Ping Test
Click Test PLC button for checking the PLC communication link.
Click Upload button.
Now all tag value read from PLC and value saved to excel file (.xls)
Final upload file saved to selected excel file location.

Final Excel Data

Excel data download to PLC

Open the Logix Data Transfer Utility software.
Click Open Button. Then Select the tag list and data excel file (.xls)
Then enter the PLC IP address and PLC slot number.
Click Ping button for checking the PLC ping or not.
Click Test PLC button for checking the PLC communication link.
Click Download button.
Now all tag value read from excel file and value download to PLC.

Support PLC's

Controllogix

1756-L61 to L65
1756-L71 to L75
1756-L81E to L85E

Compactlogix

L16ER
L18ER
L24ER
L27ER
L30ER
L31E
L32E
L33ER
L36ER
L43
L45

Advantages

No need any PLC related software like Rslinx, OPC server, Rslogix and etc.
User friendly software
Easy setup for PLC communication

DOWNLOAD SOFTWARE

How to Install

1. Extract the Logix Data Transfer Utility.rar file

2. First install vc_redist.x86.exe

3. Second install Logix Data Transfer Utility.exe

Release Note

Release date :06-12-2020

Version : V1.0

Initial released

Yaskawa Drive Connect to Allen Bradley PLC Rslogix 5000

Yaskawa Drive (V1000, A1000, GA500, GA700) connect to AllenBradly PLC (Controllogix and Compactlogix). Configuration without EDS file installation using Rslogix 5000 Version 16 and later.

Supported Drive:

V1000 (Tested)
A1000 (Tested)
GA500 (Not Tested)
GA700 (Not Tested)

Requirements:

Rslogix 5000 Version 16 and later, Studio 5000 Version 21 and later
Yaskawa Drive User Defined Data Type Download
Drive A1000 or V1000 and Ethernet Card SI-EN3
Prepare the A1000 drive parameters. How to parameter Upload and Download. Download Drive Parameter file.

Procedure:

Open the Studio 5000 program (Offline)
Right click Ethernet network card and select New module
Select Generic Ethernet Module and Click Create button
Fill the require information in dialog box
Enter the Requested Packet Interval (RPI) in your requirements
Right Click the User Define and select the Import Data Type
Now import User Defined Data Type
Open the routine add two COP instructions. First COP Source is (Conveyor_1:I) Drive input data, Destination is (Conv_1_IN) Local Data with description. Second COP Source is (Conv_1_OUT) Local Data with description, Destination is (Conveyor_1:O) Drive output data.
Create new tag Conv_1_IN with IN_DATA_A1000 data type and Conv_1_OUT with OUT_DATA_A1000 data type.
Sample program to RUN in Forward and Reverse.

VFD Startup after long shutdown

To ensure the better performance of VFD, Startup is very essential to avoid the unexpected damage or failures after a long/short shutdowns. Following startup maintenance of VFD and field devices must be carried out during the startups.

Checking and Cleaning

Check if drive or panel is free from Dust,Oil, Mist and Harmful gases,Liquid

Clean & remove the clogs if any in the VFD panel air suction louvers

Use a suction type Vacuum pump to remove any dust content settled down or to remove spider cobwebs if any present around the panel or VFD

Check the Conditions of all cable free from Damage/Cut

Check the drive cooling fan working condition

Check and Clean the VFD Heat-sink for better heat dissipation

Ensure that no cable cut pieces or wire strands are lying near or inside VFD panel

Inspection of the VFD and Field conditions

VFD to Field device

Verify the tightness of Power cable and Earth Cable

Check the continuity of input and output cables for any damage caused due to unwanted circumstances

Check VFD I/O terminals and relay output cables tightness

Check the cable tightness of Field Inputs and outputs

Components requiring lubrication must be re-inspected for dried up lubrication to prevent mechanical failures while powering on

Check the tightness of cables and presence of rust on the components. Verify resistance of the DBR before powering on (If DBR presence)

Check all brake/mechanical interlocks controlled by the VFD are properly wired and are functioning properly

Visually check the condition of Motor winding and Cables for any sign of damage or corrosion

Earthing Test

Earth testing using ohm meter

Ensure to measure earthing resistance in the main earth pit against next pit after removing VFD earthing by using milli Ohm meter. Confirm ground resistance value of 5 Ohms or less as per IEEE standard

Ensure to check the continuity of main Earth pit, motor earthing, panel earthing and VFD earthing. All should be in equipotential line

IR Test

Insulation resistance b.w terminals

Disconnect VFD output cables and keep motor is connected

Carry out the Megger test against U, V, W cable terminals with respect to Earthing and note the reading. (Test voltage 500/1000V)

Insulation resistance should be >1MΩ for a duration of 3 seconds

Caution:

Do not use Megger to VFD as it may damage the VFD internal components

VFD Cold Test

With the help of a True RMS multi-meter which has Diode mode available, perform a cold check on the Diode and IGBT on the VFD before powering on.

Click here to know how to carry out VFD cold test

After Powering up the VFD

Powered VFD to field

Power-up the VFD without any Run command for 15 minutes and allow the capacitor to charge uniformly.

Check the DC bus voltage. It should be 560 ~ 570 VDC

Check any abnormal noise,vibration or abnormal in operations

Before giving the Run command ensure all interlocks are working as per requirement

After all checkpoints are verified, run the equipment on no load condition and observe the operation for 30 Mins for any abnormality

Check motor direction when forward/reverse command is fed

Check and perform No load operation and check VFD No load current.

Run the motor at slow speed and check the performance then gradually increase speed and check the operations

Check for excessive vibration and shock loading

Measure & confirm the currents are balanced in each phase (U, V, W) after full load or desire load of process requirement

if everything is found ok, Resume normal operation

Cold Test for VFD

With the help of a True RMS multi-meter which has Diode mode available, perform a cold check on the Diode and IGBT on the VFD before powering on. Keep the negative and positive lead of the multimeter as per the tables given below to check the healthiness of Diode and IGBT respectively.

Diode Symbol in True RMS Multimeter

Input Diode Test

Step No	Multimeter (+Lead)	Multimeter (- Lead)	Expected Reading
1	R/L1 Terminal S/L2 Terminal T/L3 Terminal	DC Bus Terminal (+)	Approximately 0.5 Volts
2	R/L1 Terminal S/L2 Terminal T/L3 Terminal	DC Bus Terminal (-)	OL Displayed
3	DC Bus Terminal (-)	R/L1 Terminal S/L2 Terminal T/L3 Terminal	Approximately 0.5 Volts
4	DC Bus Terminal (+)	R/L1 Terminal S/L2 Terminal T/L3 Terminal	OL Displayed

Input Diode Test -R/L1 terminal to (-) terminal

Ouptut IGBT Test

Step No	Multimeter (+Lead)	Multimeter (- Lead)	Expected Reading
1	U/T1 Terminal V/T2 Terminal W/T3 Terminal	DC Bus Terminal (+)	Approximately 0.5 Volts
2	U/T1 Terminal V/T2 Terminal W/T3 Terminal	DC Bus Terminal (-)	OL Displayed
3	DC Bus Terminal (-)	U/T1 Terminal V/T2 Terminal W/T3 Terminal	Approximately 0.5 Volts
4	DC Bus Terminal (+)	U/T1 Terminal V/T2 Terminal W/T3 Terminal	OL Displayed

Ouptut IGBT Test (+) terminal to W/T3 terminal

NOTE : The value maybe varied when measuring the different VFD