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Replacement Micromaster MM4 6SE6440-2AD32-2DA1 F0002 F0090 Encoder Module

Created by: mrgent at: 11/17/2011 3:32 PM (3 Replies)

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11/17/2011 3:32 PM	Rate (0)
mrgent Regular Member Joined: 7/9/2008 Last visit: 4/16/2025 Posts: 12 Rating: (0)	We have needed to replace Micromaster6SE6440-2AD32-2DA1 utilizes Encoder Module6SE6400-0EN00-0AA0. We are still able to access Parameters in the defectiveMicromaster6SE6440-2AD32-2DA1. We used AOP to copy parameters from old to replacement (reconditioned) inverter. AOP is VersionA07/1.60 (I read that this later version does copy all 4 levels of parameters). We have qty 2 encoder module Old and New (New was purchased as we first suspected it was faulty when diagnosing '-----' frozen keypad on the Old Inverter. Application: Fan Blade Hub Grinding Wheel. Problem we are experiencing since replacement inverter programmed from AOP as follows: With new encoder module fitted, on enabling the inverter motor turns briefly then trips , displays F0090 speed difference out of range. P0492=3.67. For test purposes we setP0492=0 dissable speed detection, on retest the motor runs in the correct direction, under good speed control with minor instability (suspect this is due to lack of encoder feedback). We confirm encoder wirring is good, LED's on encoder module CHA & CHB flicker when motor shaft turned. We replace encoder module with the old original. On enabling we experience loud knock knock vibration as the motor moves left right and trips, displaying F0002 DC Bus Over Voltage. We suspect this is due to very rapid accel decel! LED's on encoder module CHA & CHB flicker when motor shaft turned. We are stuck as to where to look now. Further info: The fault with the original old inverter was'-----' frozen keypad, but only when encoder module fitted. If encoder module removed and replaced with keypad only fitted directly onto the inverter the keypad worked. Hence we suspected fault with the encoder module. However New encoder module gave us the same symptom. Further investigation found fault with Inverter's internal PSU, we repaired this in the workshop. The repair was good and the keypad now works when fitted with the encoder module. BUT during the investigation another problem developed which we suspect was caused by BENT PINS when fitting encoder module many times. This old inverter now has a permanent fault: Warning DC Link Under Voltage. r0026 'filtered DC-link volt' reads 3-4 volts, however we measure 617VDC at the DC Bus terminals. We have traced the DC bus detection within the inverter to the isolation IC, we replaced the IC but the symptom remained the same. Therefore we suspect the fault lies within the Inverter CPU A/D circuit. This is why we have had to replace the inverter. Bent pins is documented on the Siemens tech support site as being a common issue due to poop design. We are now desperate as this m/c has been down a week. Any advice greatly appreciated.

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11/17/2011 4:42 PM	Rate (0)
JensS Posts: 739 Rating: (55)	The fault with the original old inverter was '-----' frozen keypad, ........ = defective voltage supply; see http://support.automation.siemens.com/WW/view/en/26435762 displays F0090 = encoder lost (see: p0492 and "----") When changing the inverter, a setup by "copy and paste" (using AOP) is not enough. A set up of motor parameter and control parameter is needed.
JensS Posts: 739 Rating: (55)
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11/17/2011 6:12 PM	Rate (0)
mrgent Regular Member Joined: 7/9/2008 Last visit: 4/16/2025 Posts: 12 Rating: (0)	We have proven Encoder signal to Inverter is good by monitoring r0061 with r0021 F0090 r0947= 090 Fault message storeage area r0949 =7 associated error value Please , what is the meaning of value 7, this is not listed in the manual. Tommorow we will carry out motor tuning.

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11/18/2011 9:46 AM	Rate (0)
JensS Posts: 739 Rating: (55)	Hi, as I allready metioned, you have to do a new motor data setup. To find the Alarm values pls. see F0041. F0041 Motor Data Identification Failure Cause: Alarm value = 0: Load missing Alarm value = 1: Current limit level reached during identification. Alarm value = 2: Identified stator resistance less than 0.1% or greater than 100%. Alarm value = 3: Identified rotor resistance less than 0.1% or greater than 100%. Alarm value = 4: Identified stator reactance less than 50% and greater than 500% Alarm value = 5: Identified main reactance less than 50% and greater than 500% Alarm value = 6: Identified rotor time constant less than 10ms or greater than 5s *Alarm value = 7: Identified total leakage reactance less than 5% and greater than 50%* Alarm value = 8: Identified stator leakage reactance less than 25% and greater than 250% Alarm value = 9: Identified rotor leakage inductance less than 25% and greater than 250% Alarm value = 20: Identified IGBT on-voltage less than 0.5 or greater than 10V Alarm value = 30: Current controller at voltage limit Alarm value = 40: Inconsistence of identified data set, at least one identification failed Percentage values based on the impedance Zb = Vmot,nom / sqrt(3) / Imot,nom
JensS Posts: 739 Rating: (55)
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