We recently had a customer install a replacement 6SN1121-0BA11-0AA1 card into a 6SN1123-1AA00-0EA1 power module. When they installed the card it came up with an F-16 alarm code on the display of it, which references an “Illegal Power Module.” Using the instructions in the manual for the start-up of a replacement Simodrive card or power module we were able to get the customer back up and running with the steps below.
X171: Terminal NS1–NS2 (coil circuit of the internal line supply– and pre–charging contactor):
– is used to electrically isolate from the line supply (signal contact, terminals 111–213 must be interrogated)
– may only be switched if terminal 48 is open–circuit
terminal 48: Start
– has the highest priority
– Sequence: Pre–charging ON interrogation VDClinkw310V and VDClinkw√2*Vsupply–50V
> 500ms pre–charging contactor OUT, interrogation whether OUT, main contactor IN
>1s internal enable signals (for I/R and module group)
– saved during pre–charging
terminal 63: Pulse enable
– has the highest priority for pulse enable of all the modules
– acts instantaneously (without delay)
Terminal 64: Drive enable
– acts instantaneously on all modules
– when the signal is withdrawn, nset is set to 0 for all drives, and
> for main spindle drive / induction motor module 611 A, the pulses are canceled
after a speed, which can be set, is fallen below. The drive is braked along the ramp.
> for feed drives 611 A, after the selected timer stages have expired (as supplied: 240ms) all of the controllers and pulses are inhibited. The drive brakes along the current limit.
> for 611D drives, the pulses are deleted after a selectable speed has been fallen below and/or a time which can be set, has expired. The drive brakes along the set limits. (For spindles, a ramp can be achieved via regenerative limiting [kW])
terminal 112: Setting–up operation (Vmin3–ph. 24V AC or 34 V DC)
– the VDClink
– closed–loop control is inhibited
– regenerative feedback is not possible, i.e. when braking, VDClink can be >600V!
– this function is interrogated with the start inhibit signal, terminal AS1–AS2.
terminals AS1–AS2: start inhibit signal
– terminals AS1–AS2 closed means ”start inhibit is effective” (setting–up operation) terminals 111, 113, 213: signal contact, internal line contactor
– terminals 111 – 113: NO contact
– terminals 111 – 213: NC contact
terminal 19: FR–:
– reference ground, enable voltage
– floating (connected to the general reference ground, terminal 15 via 10kΩ)
– it is not permissible to connect terminal 19 with terminal 15 (connect to PE rail or X131)
terminal 9: FR+:
– 24V enable voltage
– max. load capability of the power supply:500mA (corresponds to 8 slots;1 optocoupler input
X 141: electronic voltages:
– terminal 7: P24 +20.4 to 28.8V / 50mA
– terminal 45: P15 +15V / 10mA
– terminal 44: N15 –15V / 10mA
– terminal 10: N24 –20.4 to 28.8V / 50mA
– terminal 15: M 0V
– it is not permissible to connect terminal 15 to PE (ground loop)
– it is not permissible to connect terminal 15 with terminal 19 (short–circuit via reactor, which internally connects terminal 15 with X131)
terminal L1–L2 for 80kW and 120kW – I/R
– is used to supply the coil of the internal line contactor
– is supplied directly at the line supply with 2–ph. 400V AC (not between I/R and reactor)
– fuse: INw4 A, type gLFan connection for 80 and 120kW I/R
– 3–ph. 360 to 510V AC , 45–65 Hz directly at the line supply (not between the I/R and reactor)
– observe the rotating field (phase sequence)!
– fuse: INw1.5 A (motor protection circuit–breaker)
– conductor connection with additional connection of the power supply at the DC link
– for this operating mode, terminals 2U1, 2V1 and 2W1 of the power supply must be supplied with the line supply voltage between the series reactor and I/R, otherwise the power supply will be destroyed! This is also valid for the monitoring modules!
After you are sure that the DC Bus has safely discharged , a DVM on the Diode scale can be used to detect if a short circuit or open exists in the power section. Readings will vary with module size.
Note: P600 and M600 are the 600 V DC Bus connections. U2, V2 and W2 are the motor connections.
• Disconnect the P600, M600 bus bars, U2, V2 and W2 connections. This isolates the power module from the motor and DC Bus.
• Diode check between P600 and U2, then V2 then W2. There should be continuity with the – lead on P600 and the + lead on U2, V2 or W2. Readings should be open with the leads reversed.
• Diode check between M600 and U2, V2, W2. There should be continuity with the + lead on M600 and the – lead on U2, V2 or W2. Readings should be open with the leads reversed.
• Diode check between P600 and M600. There should be continuity with the + lead on the M600 and the – lead on P600. The reading should be open with the leads reversed.
• Diode check between U2, V2 and W2. All combinations should read open.
Note: If all readings are open the internal DC Bus fuse is open. If there is a 0Ω reading, there is a short in the power circuit.
Note 2: Because of the capacitance in the power circuit, resistance checks will indicate a charging effect. It is necessary to wait until the measurement has stabilized to determine if it is correct. If possible, it is best to use a DVM with a diode check.
The Simodrive 611 series is meant to be a converter system that is suitable for drive assemblies that can be combines with each other to enable fast and flexible synchronization of the drive performance. This will work for a number of axes on the machine and sets the Simodrive 611 productivity levels.