Mazak New Turbo X-48 mechanical or cut program problem?

[Metalmark]

I have a Mazak New Turbo X-48 Champion (1,000w) that I have been using successfully for over 5 years. I have been using Hypertherm ProNest v19 for nesting and CAD drawing of the parts I cut, which average 4,000-5,000 parts per month (from 16 ga. mild steel). Although I have had various problems with the machine over those years, I have always been able to get it going again. However, I have a new problem that I can't figure out. About a year ago, I had a problem setting the nozzle gap due to a problem with the profiler potentiometer and so I replaced it and the machine worked fine thereafter. Recently I was cutting a sheet and when the sheet was finished, I changed programs to one that I use to cut the sheet skeleton apart so that it is easier to remove from the table. The machine made one cut and lifted to move to the next cut, but when it lowered to make the cut, the head moved too far into the sheet and triggered the auto Emergency Stop function. Reset and tried again….no cigar. At the suggestion of a Mazak tech who has helped me before, I changed the potentiometer…. the nozzle crashed into the sheet and triggered the auto emergency stop again. The tech suggested I change the “gold box’” that is used to fine-tune nozzle gap settings. No change. I also thought it might be a glitch in the program, so I tried several programs I have cut successfully many times before, but the problem still exists. I am at my wits end. Any help out there?

 

[Metalmark]

I have been out with COVID and just got back to the shop a few days ago. I still not been able to get the machine going, despite tracing all the potentiometer wiring, changing out the air cylinder, changing out the air solenoid, and changing out the proximity sensor for the X-axis. All seems to be functioning correctly. Can anyone out there offer and suggestions or help???

 

[3DDave]

Perhaps the problem is on a control board. What is the actual age of the machine? If it's closer to 10 years, I'd be looking at failures of electrolytic capacitors or any chip capacitors which can crack. Likewise the small format resistors can also develop cracks, changing their characteristics.

 

[Metalmark]

3DDave,
Thanks for your response. The machine was made in 1996, so your suggestion makes sense. The technician I have been talking to has suggested the same issue, but we have been trying to eliminate all other issues before changing out boards, which are expensive and only available used.