Simodrive 611 Trouble Shooting/Repair

We have a CNC Router that uses a Simodrive 611 to run the main spindle.  I was upgrading to a new spindle since the old one (that failed) has been out of production for 15yrs.  The new spindle matches the old one pretty closely for speed and out put rating, so I thought it would be a direct replacement.  After installing, I started the spindle a few times at lower speeds to test rotation and that everything seemed to be correct.  Then I started to run in the new spindle. Started the run in program and came back a bit later to find the control error-ed out, and all 3 fuses to the Simodrive unit blown.  We opened the power infeed unit of the Simodrive and found 2 of the IGBTs were blown.  We replaced them. Now the drive powers up and shows (___run) on the operators pannel, but I cant get it to start the spindle.  It Shows no errors, and the power infeed unit has the lower left red LED lit.  Any further hints as to what might be broken?

(Edit) I thought we had it powering up correctly, but it is still blowing one of the fuses at power up (I thought I checked that it was powering up on all 3 phases but I was mistaken.)  So we need to recheck the IGBTs again.  We may have to give up and buy another infeed unit.

 Thought I should add the part numbers of the components involved.

Infeed:  6SN1145-1BA01-0BA1

Drive:  6SN1118-0NJ00-0AA2

Power Section:  6SN1123-1AA00-0LA0

ToddZ

We have a CNC Router that uses a Simodrive 611 to run the main spindle.  I was upgrading to a new spindle since the old one (that failed) has been out of production for 15yrs.  The new spindle matches the old one pretty closely for speed and out put rating, so I thought it would be a direct replacement.  After installing, I started the spindle a few times at lower speeds to test rotation and that everything seemed to be correct.  Then I started to run in the new spindle. Started the run in program and came back a bit later to find the control error-ed out, and all 3 fuses to the Simodrive unit blown.  We opened the power infeed unit of the Simodrive and found 2 of the IGBTs were blown.  We replaced them. Now the drive powers up and shows (___run) on the operators pannel, but I cant get it to start the spindle.  It Shows no errors, and the power infeed unit has the lower left red LED lit.  Any further hints as to what might be broken?

(Edit) I thought we had it powering up correctly, but it is still blowing one of the fuses at power up (I thought I checked that it was powering up on all 3 phases but I was mistaken.)  So we need to recheck the IGBTs again.  We may have to give up and buy another infeed unit.

nulizhang

Infeed:  6SN1145-1BA01-0BA1--16KW E/R module

Drive:  6SN1118-0NJ00-0AA2--SIMODRIVE 611U 1 ax control card for resolver feedback

Power Section:  6SN1123-1AA00-0LA0--611 Powersection 108A

I give all your Siemens items the detail name, I don't know what is your question for your post.

From you picture and descrition, means your E/R module defective --the error showing missing phase

apart from Siemens componets --I see you have 3rd party devices, 1 st al make sure E/R module input 3 phase is good.

You don't give detail for spindle motor, and who make drive start up for you (or youself)

Even i know how to repair E/R module, but Siemens also the fourm here we DO NOT suport customer repair question. I suggest you order good E/R module and check insulation and pahse resistor banlace for your spindle motor, before test spindle again

We replaced the E/R module.  But that still hasn't gotten it back to where I started when things all went wrong.

The E/R module we bought was a used one though, so I can't say with 100% certainty that it is a good one.  The Machine is a Komo Mach3 CNC router.  The original spindle was a 13kw Gamfior water cooled spindle that was pretty much exclusively used only by Komo and has been out of production for more than 15yrs.  The spindle I am trying to retrofit is a Hiteco.  (Attached are parameter settings Hiteco gave me.) 

I didn't have those parameter settings when I first blew this up.  I was trying to run it with the original parameters Komo set up for the Gamfior spindle.

Any way, now with the new E/R module I have only the yellow LED on.  When I try to start the spindle it does not spin up to speed.  It did turn a little bit but soon stopped and was making a buzzing noise.  I stopped it as quickly as I could, and there was a burned smell in the control cabinet.  I had similar results both using the new Hiteco settings and the original Gamfior settings.  Originally when I first tried to run it (before the old E/R module died) it started fine the first few times that I tried to start it at 6000rpm to test the rotation direction. There is still something very wrong that wasn't before.

Our spindle has no feed back, it is just a high speed induction motor.  This is it, https://www.hiteco.net/en_US/products/electrospindles-a.t.c.c8190/serie-powertech-400-10---13-kw.8205/qe-2-9-6-12-63f-nc-cb.100602

I'll perform the tests you suggest and get back to you with the results.

What size motor would you consider a "middle size" one?

I temporarily connected a 15hp(11kw) ordinary induction motor, programmed the drive for it, and then I tried to start it.  It took me a couple of tries to get the hang of what was going on in the SimocomU interface.  The first couple of times I tried to start it, it was only commanding it to run at a couple hundred RPM, and the motor would only turn a fraction of a turn, stop and turn a little more...  Then I realized the RPM at the top of the window should be set for the full speed of the motor and then I use the slider at the side of the screen for the output speed.  After doing that and setting the commanded speed for 800rpm, the motor only turned a fraction of a turn then stopped and the drive showed an alarm 608.  Tried this a few times monitoring the current on each lead to the motor and one of the 3 leads never showed any current, the other 2 leads would show blips of 3-8 amps (motor is rated for 18a.)

Does the problem most likely lie in the drive module or the output power section?  The drive is a 6SN1118-0NJ00-0AA2, and the power section is a 6SN1123-1AA00-0LA0 (108A)

I don't know a huge amount about the drive's history.  We have only had the machine it is in for about 2.5years.  It is installed in a Komo Mach3 CNC router that was built new in 2003, to run a 13kw Gamfior liquid cooled "Woodchuck" spindle.  We bought the machine used in 2021.  We had to have the spindle rebuilt soon after we bought the machine, and we've been running the machine since.  Then a few weeks ago the spindle seized up, and we decided to retrofit this Hiteco spindle rather than sending out the old one to be rebuilt again.  We are using this same model Hiteco spindle on several other machines and we keep a spare on the shelf.  So the retrofit made sense rather than trying to rebuild an old discontinued spindle that may not even be rebuildable due to discontinued part availability.  (Also the cost of the last rebuild was nearly as much as the new spindle and that time it wasn't seized only running rough.) 

The problems with the drive began after installing the new spindle.

All of the other machines we have running this Hiteco spindle are using Yaskawa drives, I had zero experience working with Siemens drives before this.  All of which were using different spindles and I retrofitted them with this Hiteco one.  One of those I did have to upgrade to a newer, larger drive.  But right now buying a replacement drive capable of running a 13kw router spindle at 800hz is very painful.  We had one on order for 11 months before we ended up giving up (after projected shipment had been pushed back 3 months for the 3rd time) canceling the order and bought a used one off ebay.