Hello I am new to this forum but I hoped that someone might be able to help me with an issue we are having with a Thibault 180T CNC machine used for milling stone products. It is controlled by Sinumerik.

We have a Simodrive 611 U/E module 6SN1146-1AB00-0BA1 linked with two LT modules 6SN1118-1NK01-0AA0 and 6SN1118-1NJ01-0AA0. Between them 3 axes are controlled X,Y,Z.

When the machine arrived a representative from Thibaut came to commission the machine and another engineer came to give the staff some training on how to operate this particular type of machine. During the training a fault became apparent with the inverter causing no operation of the spindle. At this point the machine could still jog on XYZ axis. 

The inverter was sent for repair and was refitted when it returned. Since then the U/E module has flashing warning lights.

15 Volt Supply

5 Volt Supply

External (Green) LED

The yellow LED does not light.

When the machine was started the HMI software came up with several errors (I have attached pictures for reference) but mainly 25202 Waiting for Drive error but also 25201 Drive Fault 26101 Drive Communication failure. I also got initially error code 510113 'Thibaut: Alarme 14: POWER 611U Defect'. I have yellow text in bottom left of screen displaying 'Communications to NC failed'.

I have restarted the machine and since this only error 25202 Axis Z Waiting for Drive is present.

There are lights on at the control interface on the spindle but no lights when pressing any of X+/- Y+/- Z+/- so communication from the cabinet to spindle.

When the button to activate the controls on the spindle is pressed there is a protector preventing the switch from latching.

What I have tested:

Disconnected ribbon cables and Bus bar between U/E and two LT modules - LEDs still flash.

Disconnected block connectors on 611 U/E fault is present until block connector for P600, M600 and 3 phase shorts is removed. I presume this is normal. 

I have tested voltages on terminals from the documentation and they seem to be either low or none existent. On 24VDC I have a sporadic voltage ranging from 6-11 VDC I also noticed that there was a leakage onto some 0V rails of between 1 and 2VDC.

I tested the inverter output voltages. There is no voltage on the U1 V1 W1 output to spindle. Everything other output voltage is normal.

To my mind everything points to fault in the U/E module. I have stripped it down and there is nothing obvious. I have tested the ribbon cable all is good with that.

Am I right in my judgement that there is a fault in the U/E module? Are there any other external components I should be checking? I have provided a variety of images at the below URLs and I am able to give more information if anyone is able to advise me further.

http://www.trisymmetry.co.uk/thibaut/1.JPG

http://www.trisymmetry.co.uk/thibaut/2.JPG

http://www.trisymmetry.co.uk/thibaut/3.JPG

http://www.trisymmetry.co.uk/thibaut/4.JPG

http://www.trisymmetry.co.uk/thibaut/5.JPG

http://www.trisymmetry.co.uk/thibaut/6.JPG

http://www.trisymmetry.co.uk/thibaut/7.JPG

http://www.trisymmetry.co.uk/thibaut/8.JPG

http://www.trisymmetry.co.uk/thibaut/9.JPG

http://www.trisymmetry.co.uk/thibaut/10.JPG

Any help would be very much appreciated.

Regards,

Tom.

Hello,

Have you checked the DIP switch settings of the infeed module. (On top left side)

Please refer the attached sheet & confirm the setting of DIP switches as per site conditions.

The pictures (links provided in your post) are not available. 

Any way the fault messages are related with infeed & drive LT modules. So please check the DIP switch setting & power LT modules.

HTH.

PISCEAN 2010

Hello,

Have you checked the DIP switch settings of the infeed module. (On top left side)

Please refer the attached sheet & confirm the setting of DIP switches as per site conditions.

The pictures (links provided in your post) are not available. 

Any way the fault messages are related with infeed & drive LT modules. So please check the DIP switch setting & power LT modules.

HTH.

 Hi Piscean,

Thanks for your response. The switch is set for 415VAC and the UVW voltages have been tested at between 235-240v at block connector X181 on the UE.

When connected to the UE module the LT modules have R F lights flashing.

I will check LT modules and feed back.

The links are now working there was a spelling error in them.

Thanks,

Tom.

Tom B

 

PISCEAN 2010

HTH.

 Hi Piscean,

....the UVW voltages have been tested at between 235-240v at block connector X181 on the UE.

Thanks,

Tom.

 Hello,

At X181 connector 2U1, 2V1, 2W1 supply must be 415V 3 phase. Please check. (Is there short links between 2U1 - 1U1; 2V1-1V1; 2W1-1W1)

PISCEAN 2010

 

Tom B

 

PISCEAN 2010

HTH.

 Hi Piscean,

....the UVW voltages have been tested at between 235-240v at block connector X181 on the UE.

Thanks,

Tom.

 Hello,

At X181 connector 2U1, 2V1, 2W1 supply must be 415V 3 phase. Please check. (Is there short links between 2U1 - 1U1; 2V1-1V1; 2W1-1W1)

 Hello,

There are short links between each phase as suggested. I measured each phase to ground and get 240V roughly.

Tom.

OK.

Have you checked the infeed & power LT modules with multi-meter for short circuit?

Please refer this post for additional information. 

 your S1 setting for UE and voltage seems OK--240*1.732=415V. BUT.

Don't measuring each phase to ground, check Line  to line--2u1-2v1-2w1, ( or U1-V1; V1-W1;W1-U1)

they should be not lower than 380VAC, (I attached picture for 10/25 KW) . 5/10KW power leads U1,V1,W1, are under PS box, small connector --like LT module connectors.

and I suggest you test you power transformer output line to line voltage to you UE module ( disconnect UE module )

post result here. I will give you help

Tom B

 

PISCEAN 2010

 

Tom B

 

PISCEAN 2010

HTH.

 Hi Piscean,

....the UVW voltages have been tested at between 235-240v at block connector X181 on the UE.

Thanks,

Tom.

 Hello,

At X181 connector 2U1, 2V1, 2W1 supply must be 415V 3 phase. Please check. (Is there short links between 2U1 - 1U1; 2V1-1V1; 2W1-1W1)

 Hello,

There are short links between each phase as suggested. I measured each phase to ground and get 240V roughly.

Tom.

Hi Nulizhang,

Thanks for your response. 

The voltages seem to be within the normal range.

I have totally isolated all other modules (LT Modules) so the only module powering up is the UE module. Doesn't this suggest that the UE module is the root cause of the problem or have I missed something other than this within the system that could be a contributing factor?

Thanks,

Tom.

 if the voltage in the rang, then as your 1st post described problem--it is very clean the UE (power supply module) defective.--that is the root of all other alarms.

If m/c in warranty ask dealer send your a replacement of 5/10KW UE module.

if m/c out of warranty don't let them repair UE module , buy a used one for less than $800 usd from market.

If you like you can  send me PM for more spare parts information--I have all Siemens parts your m/c using.

PS: I re checked all pictures you attached  in the 1st post and have 2 questions-- 

#1--you did not post picture of your UE module faulty--LED's flashing?

#2--Do you know what kind of CNC system your m/c used?--I think it is 840Di?

Tom B

Hi Nulizhang,

Thanks for your response. 

The voltages seem to be within the normal range.

I have totally isolated all other modules (LT Modules) so the only module powering up is the UE module. Doesn't this suggest that the UE module is the root cause of the problem or have I missed something other than this within the system that could be a contributing factor?

Thanks,

Tom.

Hi,

Yes the LEDs were flashing,  all 3.

I've mocked up an image quickly to show which LEDs are flashing.

And yes it is 840 Di.

Tom.

 your UE module defective for sure and I think its low voltage control part inside issue. so all other function no good, that give you all other alarms

you need install good UE module to see every thing OK or may have other issue

if you need spare parts information you can PM me.

Tom B

Hi,

Yes the LEDs were flashing,  all 3.

I've mocked up an image quickly to show which LEDs are flashing.

And yes it is 840 Di.

Tom.

A brief update.

the 611 UE was repaired and refitted.

UE acts normally but when pressing the switch to activate XYZ controls a protection device is preventing switch from latching.

Does anybody have any further thoughts?

I have attached picture of switch (white one).

thanks,

Tom

Which is the controller? 840D or 840Di? PL or SL?

Alarm no 510113 displayed in your case is PLC alarm. Check DB2.DBB3.5. 

You need Simatic manager step 7 V 5.4 at-least. MPI data cable & PG or PC with CP to go online with Simatic manager so as to analyse the problem.

HTH. 

 If you need more help you need post more information, the 2 pictures you post are not important--I need to see the picture of UE module (that is your power supply---I just post one tip post in CNC branch using your case as example) --how can you say UE module fixed --show the picture here, and do you check DC link voltage? 600VDC --do you check ter. 72/73-- I see OEM alarm 5xxxxx--text 611U power defective. if it is true--that mean your UE module still has issue.

we need more story about your m/c--840Di control 61U how many axis? what happy ? you get an  2nd hand m/c? or it is running good before UE defective?

you questions are not easy to answer, as we have no information and not at your present.  

Tom B

I also have this alarm as displayed in the attached image

 Hi, di you problem fix? if not and you want to get help you need post more info. such as picture of Power supply--UE module in working--enable, what color of LED's on.

fro your post --alarm it is very possible UE module not fixed.

Tom B

I also have this alarm as displayed in the attached image

Hi,

In the end we sent the unit for diagnosis and repair. According to the engineer that repaired it there were defective rectifier diodes in the unit.

Many thanks for all of your responses they were very helpful.

Tom