Update: White Vector unit smoked out and faulted again.
We pulled the Drive and the cover off the Drive unit. The VF ran for about 5 hours (recently back from repair). We had ran a warm up pgm earlier in the day. A few times went Jogging around as we tested some distances on workholding'. The machine was sitting idle for about 2 hours when it failed. Nothing else running. A small tantalum cap fell out and was sitting below it.
Seems like something in Spindle Motor output area failed...
Attached is a link to a non-haas provided spindle drive print that's been shared around for years. Close enough to help map this to places to look around for what might be causing this.
Here is the full PDF. https://drive.google.com/open?id=1ix...spPd9rPLWyljdt ) Or- PAge 2 JPG image below.
(pic below) The Part that fell out, C61, is from J11 connector, and C60 from J12 browned and toasty. Semiconductor wise: a VR Diode popped between the black IC type modules near J11/J12. The output of J11/12 and J9/10 on page 2 show they end up on the A' B' C' motor connection lugs. Ohm'ed that part out. Seems right.
BUT... what's it all mean? Something external must be causing this now... 2nd time it's done this and 2x time repaired externally.
MEGGER test of the motor? (bought a cheap import.. but seems to work well enough). I did the test right from the 3 motor cables where they connect to the drive? Do I need to get all the skins off again and get up top?
500V insulation test - all 3 leads. 1.96 to 2 GigOhm. All three leads read nearly identical.
1000V insulation test - All 3 least. 1.87-1.9 GigOhms. All three leads read nearly identical.
Did not perform the 2500 or 5000v insulation tests but can.
Other than the MEgger test, Not sure what else we can check or should do next? Ohmed out all the 380VDc lines to and axis motors. checked everything I could to ground looking for shorts.... Spindle wise, wondered if someone else might have some thoughts. It's no a production machine. For a Sons COllege program and maybe a start-up if it'll ever run. been a terrible year w/ this thing.
Pic of area missing cap bad VRx device;
Pic of sheet 2. Schemo-