I have for years pulled information from PM and figured it was time to give back 
.
We recently purchase a 1988 Mazak QT8 year 1988 and the thread is hopefully to serve as a play by play of some issues we are encountering/working thru to get it back up and running.
So I'll start it off and please anyone chime in if I say something inaccurate as this is the my first Mazak.
Upon receiving the machine and checking the transform taps. The machine was set up with the jumpers to support 200V, our power is 215 3 phase. The taps were changed to support incoming power outlined by the 220V tap information located behind the right side access cover if standing at the front of the machine.
The phasing was determined by verifying the correct rotation of the hydraulics. Didnt get it the first time, coin flip, second time were good rotation corrected. Sounds good.
Powered up at the control everything came active parameters intact from transit time. And now for the fun. There is a 20 NMI E stop and 204 spindle controller malfunction.
The drive is a FR-SFJ for reference. The led led will blink for just a second upon boot up and then nothing. Checking the taps on the controller board per MEAU instruction read nothing. (just trying to eliminate a faulty led and such)
The Spindle motor UVW wires and I believe the MSI 1 & 2 wires, and 2 Honda control cables were disconnected and the powered back up in an effort to determine if there was a pinched wire or ground present that the controller was seeing and "NOT" allowing it to energize.
The above yielded no success.
Then removing the SFJ controller board (Not the entire drive, just the top board) allows access the IM-PW2 power supply. On this board there is a yellow LED that I'm assuming should become light when powered up. The three incoming legs of power R,S,T, all checked to in fact have 220V when checking between them.
This is where it gets exciting. The Main disconnect was then turned on and on only briefly as there was an electrical smoke smell. MEAU had given me a sheets for checking voltage of the power supply separate from the board as I had read on other threads if difficult to determine the cause whether it be the board or the power supply. Well it would appear the power supply might be in fact the issue.
The attached pictures are what appear to be a a result of a corrosion short underneath the white 12pin plug, with this plug pryed up and off there was what seemed to be a residue oil and mixture of black. I'm leaning towards hopefully a dielectric capacitor leaded out over time but additionally while looking into the very small pin female socket the terminals are residue of blue indicating corrosion.
This is where I value opinions gentlemen, my hypothesis is yes there was a corrosion resistance short that occurred and its not pretty. I believe this happened due to the control board being removed and there was nothing to "fault check" that everything was online and talking to each other, it saw an open loop and never let the power supply energize completely. With the board removed, the power supply went ahead and powered up and thus the short that was present now went ahead and had real power applied to it and poof. I'm going to be changing the capacitors and repairing the trace in this isolated area and making another attempt to power up the supply side less the control board.
If I'm incorrect in my approach and or any input or suggestions are welcomed. This condition seems to have been in the machine for a while because the machine is in beautiful condition physical wise, it saw very light use and I believe someone got the alarms a long time back and just wrote it off as dead and its floated around for a a while before someone willing to do something got a hold of it.
I'm going to try my best and would like to avoid sending the entire drive to MEAU if at all possible.
Thank you
(the scrapping on the capacitor is me checking to see if it had degassed and or blown out and this one suffered the blunt of the electrical arc and I "thought" I saw a hole, but no hole)
.We recently purchase a 1988 Mazak QT8 year 1988 and the thread is hopefully to serve as a play by play of some issues we are encountering/working thru to get it back up and running.
So I'll start it off and please anyone chime in if I say something inaccurate as this is the my first Mazak.
Upon receiving the machine and checking the transform taps. The machine was set up with the jumpers to support 200V, our power is 215 3 phase. The taps were changed to support incoming power outlined by the 220V tap information located behind the right side access cover if standing at the front of the machine.
The phasing was determined by verifying the correct rotation of the hydraulics. Didnt get it the first time, coin flip, second time were good rotation corrected. Sounds good.
Powered up at the control everything came active parameters intact from transit time. And now for the fun. There is a 20 NMI E stop and 204 spindle controller malfunction.
The drive is a FR-SFJ for reference. The led led will blink for just a second upon boot up and then nothing. Checking the taps on the controller board per MEAU instruction read nothing. (just trying to eliminate a faulty led and such)
The Spindle motor UVW wires and I believe the MSI 1 & 2 wires, and 2 Honda control cables were disconnected and the powered back up in an effort to determine if there was a pinched wire or ground present that the controller was seeing and "NOT" allowing it to energize.
The above yielded no success.
Then removing the SFJ controller board (Not the entire drive, just the top board) allows access the IM-PW2 power supply. On this board there is a yellow LED that I'm assuming should become light when powered up. The three incoming legs of power R,S,T, all checked to in fact have 220V when checking between them.
This is where it gets exciting. The Main disconnect was then turned on and on only briefly as there was an electrical smoke smell. MEAU had given me a sheets for checking voltage of the power supply separate from the board as I had read on other threads if difficult to determine the cause whether it be the board or the power supply. Well it would appear the power supply might be in fact the issue.
The attached pictures are what appear to be a a result of a corrosion short underneath the white 12pin plug, with this plug pryed up and off there was what seemed to be a residue oil and mixture of black. I'm leaning towards hopefully a dielectric capacitor leaded out over time but additionally while looking into the very small pin female socket the terminals are residue of blue indicating corrosion.
This is where I value opinions gentlemen, my hypothesis is yes there was a corrosion resistance short that occurred and its not pretty. I believe this happened due to the control board being removed and there was nothing to "fault check" that everything was online and talking to each other, it saw an open loop and never let the power supply energize completely. With the board removed, the power supply went ahead and powered up and thus the short that was present now went ahead and had real power applied to it and poof. I'm going to be changing the capacitors and repairing the trace in this isolated area and making another attempt to power up the supply side less the control board.
If I'm incorrect in my approach and or any input or suggestions are welcomed. This condition seems to have been in the machine for a while because the machine is in beautiful condition physical wise, it saw very light use and I believe someone got the alarms a long time back and just wrote it off as dead and its floated around for a a while before someone willing to do something got a hold of it.
I'm going to try my best and would like to avoid sending the entire drive to MEAU if at all possible.
Thank you
(the scrapping on the capacitor is me checking to see if it had degassed and or blown out and this one suffered the blunt of the electrical arc and I "thought" I saw a hole, but no hole)
