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Okuma OSP 5000 Electrical Maintenance, Training Manual Download Page 30

2-8

Okuma America Corporation

     

DOCUMENT

DOCUMENT

DOCUMENT

DOCUMENT

DOCUMENTA

A

A

A

ATION

TION

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TION

Rev. 1-16-01

Topic

Manual

Section

Power Requirements

Operation & Maintenance/
Maintenance

Installation/
Power Requirements

Power Transistor Insp.

Maintenance

Brushless Servo

Pre-start Checklist

Operation & Maintenance

Machine Operation

Preparation for Delivery

Operation & Maintenance

Handling & Installation

Program Format

Operation

Applications

Program Selection

Operation

Applications

Pulse Generator

Maintenance

C-Axis

Relay Layout

Maintenance

Appended Figures

Relay Inspection

Maintenance

Troubleshooting

Robot Interlock

Special Functions

Robot Interlock

RS232C

Special Functions

Tape Punch Interface

Safety Precautions

Operation & Maintenance

Safety Precautions

Sequence Number Search

Operation

Applications

Sequence Restart

Operation

Applications

Shear Pin Replacement

Operation & Maintenance

Periodic Maintenance

Skeleton Diagrams

Operation & Maintenance

Appended Diagrams

Slide Hold During Thread
Cutting

Special Functions

Slide Hold Function

Solenoid Valve Layout

Operation & Maintenance

Appendix

Spare Parts

Operation & Maintenance/
Parts Book/Elec Schem.

Spare Parts List/
D-drawings

Specifications

Operation/Oper & Maint

Specifications/General

Spindle

Diameter

Operation & Maintenance

Machine Specifications

Drive Unit

Maintenance

Spindle Drive Unit

Gear Ranges

Operation & Maintenance

Machine Specifications

Nose Dimensions

Operation & Maintenance

Technical Data

Nose Type

Operation & Maintenance

Machine Specifications

Orientation

Maintenance/Special
Functions

C-axis/Spindle Orientation

Power/Torque Chart

Operation & Maintenance

Machine Operation

Speed Range

Operation & Maintenance

Machine Specifications

Taper

Operation & Maintenance

Machine Specifications

Through Hole Size

Operation & Maintenance

Machine Specifications

Structure of OSP

Maintenance

Structure of OSP

Sub Programs

Special Functions

Sub Programs

Swing Arm Loader

Special Functions

Swing Arm Loader

SSR Output

Maintenance

Troubleshooting

Table Specifications

Operation & Maintenance

Machine Specifications

Summary of Contents for OSP 5000

Page 1: ...NG CENTER THE MACHINING CENTER THE MACHINING CENTER THE MACHINING CENTER ELECTRICAL MAINTENANCE ELECTRICAL MAINTENANCE ELECTRICAL MAINTENANCE ELECTRICAL MAINTENANCE ELECTRICAL MAINTENANCE TRAINING MAN...

Page 2: ...Intro...

Page 3: ...the OSP 5000 5020 or 500 control The course is designed to provide the information needed to diagnose any machine problem The individual will be capable of diagnosing a problem and be able to communic...

Page 4: ...N 1 Instructor and Class Introductions 2 Okuma History 3 Terminology 4 Safety One 5 Okuma Documentation Two 6 Machine Definition Three A Introduction to CNC 7 Machine Operation Four A CNC Operation Pa...

Page 5: ...ng Actual Position Pages B Using Block Data Pages C Using Check Data Pages WEDNESDAY 1 Diagnostics continued D Alarms 2 Parameters Seven A Setting Stroke End Limits B Setting Zero Offsets THURSDAY 1 S...

Page 6: ...ngle source in support of a common purpose The following is a history of Okuma s technological advancement Other milestones are noted on Okuma s path to becoming one of the world s best machine tool b...

Page 7: ...SP 5000 series 1982 Developed the machine monitoring function MOP Started using fiber optics for data communications 1983 Introduced high precision fully digital servo systems with brushless motors In...

Page 8: ...n Kani Japan Scott Nishio became president of OMT and introduced the Made In America 2 axis lathe Cadet Introduced a cam turning function NC turret and NC ATC 1992 OMT built their 3000th machine 1993...

Page 9: ...tic Logic Unit ASCII American Standard Code for Information Interchange ATC Automatic Tool Changer APC Automatic Pallet Changer BB0 Bubble memory section control software on 5000 5020 series BB1 Bubbl...

Page 10: ...erical Control DRAM Dynamic Random Access Memory EC EO I O board on Okuma Lathes and Grinders ECP Electrical Control Processor board I O control board on Okuma M C s EIA Electronics Industries Associa...

Page 11: ...tandards Organization ISO 24 Vdc Isolated 24 volts dc LAP Lathe Automatic Programming LDU Linear Drive Unit Long Word 32 bits 4 bytes 2 words MAP Machine Automatic Programming MB Main board MC Main Ca...

Page 12: ...020 RHP Rack High Power Opus power supply on 5020 RPP RS232C Printer Puncher board RSAPA Axis position when Touchsetter is detected SAOP Sub Amp Operation SCSI Serial Communication System Interface SD...

Page 13: ...1389 5 5B1D9 1389 5 5B1D9 1389 5 5B1D9 3 CDBE3D9 3 CDBE3D9 3 CDBE3D9 3 CDBE3D9 4917 CD93C 4917 CD93C 4917 CD93C 4917 CD93C 1B1 5D5BC 1B1 5D5BC 1B1 5D5BC 1B1 5D5BC C 6DG1B5 C 6DG1B5 C 6DG1B5 C 6DG1B5...

Page 14: ......

Page 15: ...OSP 5000 5020 CONTROL SAFETY ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501...

Page 16: ......

Page 17: ...s is used check the allowable maximum spindle speed and run the spindle within the allowable range Pay due attention to workpiece gripping force and balance 4 The maximum spindle speed can be limited...

Page 18: ...ng the machine 4 With a new program never attempt to start actual cutting operations First run the program without setting a workpiece in the machine to check machine operations and interference after...

Page 19: ...workpieces use a crane hoist or other tool 7 Before setting a workpiece in the machine make sure the workpiece has portions that can be used for proper chucking MACHINING CENTERS 1 Never touch the sp...

Page 20: ...main power disconnect WHEN A PROBLEM OCCURS 1 Stop all spindle s and axes movement by pushing the closest EMERGENCY STOP switch 2 Contact the maintenance person to determine what action to take 3 Use...

Page 21: ...OSP 5000 5020 CONTROL DOCUMENTATION ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501...

Page 22: ......

Page 23: ...contains information about the basic operation of the machine The file handling procedures and communication protocol are also explained in this manual The last part of this manual explains the param...

Page 24: ...accompany the machine ALARM ERROR LIST This is the alarm book which contains most of the alarms that can occur on the machine Some special alarms can be found in the Special Functions manuals PROGRAM...

Page 25: ...ion Maintenance ATC Prep of Cutting Tools Operation Maintenance ATC Tool Adjustments Operation Maintenance ATC Sequence Numbers Operation Maintenance ATC Specifications Operation Maintenance Machine S...

Page 26: ...Switch Adj Operation Maintenance Machine Operation Spindle Speed Chart Operation Maintenance Machine Operation Circular Thread Cutting Special Functions Circular Thread Cutting Consumable Items Opera...

Page 27: ...aintenance Machine Specs General Door Interlock Oper Maint Special Functions Mach Oper Front Door Interlock Door Open Close Special Functions Auto Door Open Close EC Power Supply Maintenance Troublesh...

Page 28: ...ance Handling Installation Limit Switch Insp Maintenance Troubleshooting Layout Operation Maintenance Appended Diagrams Loader Interlock Special Functions Loader Interlock Logic Table Layout Maintenan...

Page 29: ...ration Maintenance Operation Operation Operation Operation Operation Monitor Special Functions NC Operation Monitor Optional Specifications Operation Maintenance Operation OSP 5000 5020 Control Check...

Page 30: ...rams Operation Maintenance Appended Diagrams Slide Hold During Thread Cutting Special Functions Slide Hold Function Solenoid Valve Layout Operation Maintenance Appendix Spare Parts Operation Maintenan...

Page 31: ...ns Tailstock Swing Thrust Chart Operation Maintenance Machine Operation Timing Belt Adj Operation Maintenance Periodic Maintenance Working Range Diag Operation Maintenance Optional Specs Tape Data I O...

Page 32: ...ze Operation Maintenance Machine Specifications Offsets Operation Operation Troubleshooting Operation Maintenance Troubleshooting Tool Capacity Operation Maintenance Machine Specifications Type Operat...

Page 33: ...OSP 5000 5020 CONTROL MACHINE DEFINITION ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501...

Page 34: ......

Page 35: ...and the Machine Control Unit MCU The CNC improved the handling of machine data coded instructions which resulted in increased speed and accuracy of the machine tool A CNC needs at least four hardware...

Page 36: ...formation MEMORY The computer cannot run without some means of storing information There are numerous types of memory available for this purpose and they fall into one of three categories Perma nent L...

Page 37: ...Memory type device Under normal operating conditions this type of memory would lose the stored informa tion when power is shut off A device that loses stored data when power is turned off is said to b...

Page 38: ...rvo control amplifier The servo amp acting on the command signal sends the proper amount of voltage in the proper sequence to the axis or spindle motor For safety and accuracy purposes some kind of fe...

Page 39: ...re to come into contact with the disk surface or if some form of contamination were to get between the read write head and the disk it would cause damage to the ferrous material Technically tape reade...

Page 40: ...st a suitable cutting tool On lathes the tool moves along a rotating workpiece The carriage or Z axis moves the tool toward the spindle The cross slide or X axis mounted on the carriage moves the turr...

Page 41: ...le cross wise movement and is positive when fed towards the operator The Z axis is the spindle head vertical movement and is positive when fed upward Figure 3 3 shows the axis nomenclature for the hor...

Page 42: ...AL MACHINING CENTER AL MACHINING CENTER AL MACHINING CENTER AL MACHINING CENTER AL MACHINING CENTER X axis Longitudinal movement of the table positive when fed to the right Y axis Vertical movement of...

Page 43: ...LING COLUMN TYPE HORIZONT VELLING COLUMN TYPE HORIZONTAL MACHINING CENTER AL MACHINING CENTER AL MACHINING CENTER AL MACHINING CENTER AL MACHINING CENTER X axis Longitudinal movement of the table posi...

Page 44: ...CHINING CENTER DOUBLE COLUMN MACHINING CENTER DOUBLE COLUMN MACHINING CENTER DOUBLE COLUMN MACHINING CENTER X axis Longitudinal movement of the table positive when fed toward the operator Y axis Spind...

Page 45: ...ught the piece almost to size On Okuma grinders there are two types of coordinate systems One is a work coordinate system for grinding and the other is a wheel coordinate system for wheel dressing The...

Page 46: ...N MACHINE DEFINITION MACHINE DEFINITION MACHINE DEFINITION Rev 8 21 01 a Plane OD Grinding GP N GU S b Angle OD Grinding GA N GU S Work Coordinate System for OD Grinding Fig 3 6 c ID Grinding GP N GU...

Page 47: ...ACHINE DEFINITION MACHINE DEFINITION Rev 8 21 01 For External OD Grinding a Plane OD Grinding GP N GU S b Angle OD Grinding GA N GU S Wheel Coordinate System for OD Grinding For Internal ID Grinding c...

Page 48: ...OSP 5000 5020 CONTROL MACHINE OPERATION ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501...

Page 49: ......

Page 50: ...eries controls mainly consist of four panels 1 NC Operation Panel Common Panel 2 Machine Operation Panel 3 Pendant Operation Panel 4 Option Panel NC Operation Panel The NC operation panel is common on...

Page 51: ...er menus D NUMBER SEARCH RESTART SP SELECT SP N SEARCH EXTEND F1 F2 F3 F4 F5 F6 F7 F8 Used to search for the specified BLOCK DATA of the part program currently selected by turret selection also possib...

Page 52: ...match the program Used for setting the required scaling Used to quit normal scale setting C FRAME ENLARGE FRAME REDUCE SCALE QUIT F1 F2 F3 F4 F5 F6 F7 F8 Used to enlarge the frame Used for contracting...

Page 53: ...of the axes in relation to the zero offset Used to display a part program Used to display the data in one BLOCK DATA Used to display I O signals and various other data Used to access other menus A MAN...

Page 54: ...position data machine status i e chuck clamped and load conditions Simultaneous display of actual position data distance remaining to target point actual data from absolute position encoder tool offs...

Page 55: ...after the CHECK DATA function key has been pressed The following bullets describe what the different screens show Displays servo data related to individual axes Displays EC inputs machine side inputs...

Page 56: ...n pressed The following bullets describe what the different screens show The tool offsets are displayed and can also be changed in this menu Use the key to access tools 13 to 32 if applicable Displays...

Page 57: ...acity Used to display contents of the active file Used to access the IGF function option Used to access more menus TIME INIT DELETE RENAME MULTI PIP PROTECT EXTEND F1 F2 F3 F4 F5 F6 F7 F8 Used to ente...

Page 58: ...e Outputs A TOP file to peripheral device Compares data sent to or from peripheral with data in memory Used to terminate data transfer procedure ZERO SET SET ADD CAL BACK UP F1 F2 F3 F4 F5 F6 F7 F8 Us...

Page 59: ...Optional Parameter Long Word Optional Parameter Word Optional Parameter Bit Turret Angle Turret Parameter Bit Some of the screens displayed will have more than one page These pages can be accessed by...

Page 60: ...r particular Check Data screen Used to display the status of the ATC or APC Used to display I O signals and various other data Used to access other menus LIBRARY P SET TOOL DISPLAY PERSONAL DIAGNOSIS...

Page 61: ...Displays blank material Deletes graphic display Turns on or off the data displayed during graphics Turns on or off the high speed drawing mode Used to display other menus GRAPHIC GRAPHIC DATA AUTO SCA...

Page 62: ...ing Center Machining Center Machining Center Rev 8 21 01 MARKER SET QUIT F1 F2 F3 F4 F5 F6 F7 F8 Changes view point marker Ends area angle view change I SET ADD SELECT QUIT F1 F2 F3 F4 F5 F6 F7 F8 Use...

Page 63: ...nates of the actual position of the axes in relation to the zero offset Used to display a part program Used to display the data in one BLOCK DATA Used to search for particular Check Data screen Used t...

Page 64: ...multaneous display of actual position data machine status i e chuck clamped and load conditions Simultaneous display of actual position data distance remaining to target point actual data from absolut...

Page 65: ...ion Panel various screens can be accessed after the CHECK DATA function key has been pressed The following bullets describe what the different screens show PROGRAM SELECT ACTUAL POSIT PART PROGRAM BLO...

Page 66: ...and can also be changed in this menu not available for the graphics specification Use the key to access tools 13 to 32 if applicable Displays tool group data Displays post process gauging results Sett...

Page 67: ...lay the remaining memory capacity Used to display contents of the active file Used to access the IGF function option Used to access more menus TIME INIT DELETE RENAME MULTI PIP PROTECT EXTEND F1 F2 F3...

Page 68: ...P file from peripheral device Outputs A TOP file to peripheral device Compares data sent to or from peripheral with data in memory Used to terminate data transfer procedure ZERO SET SET ADD CAL BACK U...

Page 69: ...Variable System Parameters Optional Parameter Long Word Optional Parameter Word Optional Parameter Bit Turret Angle Turret Parameter Bit Some of the screens displayed will have more than one page The...

Page 70: ...s on when the control sees a program stop M00 STOP optional stop M01 or end of program code M02 This light will flicker when the control reads a dwell command G04 The duration depends on the F word pr...

Page 71: ...flicker to remind the operator which operation mode the control is in Character Keys These keys are used to input alphabetic characters and other symbols shown on the upper right side of each key To i...

Page 72: ...to start machine operation in Auto or MDI START mode SLIDE Pressing this button will stop all axes movement It will not stop HOLD spindle rotation If this button is pressed when no axis movement is ac...

Page 73: ...counter clockwise Must press the STOP button to stop the rotation CW Makes the spindle turn clockwise Must press the STOP button to stop the rotation JOG With this button pressed the spindle will rot...

Page 74: ...t the upper left corner of the ENGAGE key will light up when the gear position and confirmation limit switch match If they do not match the light will flicker at intervals of 0 4 sec This holds true w...

Page 75: ...his function activated cutting feedrate commands with the exception of manual feed and G00 mode feed are all executed at the milling feedrate mm min set by the parameter The parameter long word No 9 i...

Page 76: ...net has to be turned on first When the CONTROL ON switch is pressed the pilot lamp inside this push switch will turn on This switch is also used to reset the control CONTROL Press this switch to turn...

Page 77: ...per tool changes This key is effective with the spindle at rest or in motion Once this key is pressed the indicating lamp on the upper left corner will start to blink Once the spindle orientation is c...

Page 78: ...the tool The indication lamp on the upper left corner of the key will turn on to show that the motor is on This key is effective no matter which operation mode is on OIL MIST When this key is pressed...

Page 79: ...n The sign of the designated axis is reversed The INTERLOCK RELEASE key must be held down when turning on this function INTERLOCK This key is used to turn on certain keys on the machine operation RELE...

Page 80: ...is interrupted during automatic RESTART operation due to a tool breakage or other problem the sequence restart button is used to resume the program after the necessary measures have been taken to reso...

Page 81: ...operation is not allowed to continue and the RUN message is displayed on the CRT 1 STEP The function of this key is the same as the 1 STEP ADVANCE REVERSE key except the operation is done in reverse I...

Page 82: ...uestion Optional Panel This panel is for switches and lamps related to the optional functions that can be purchased with the machine An example of an option panel would be a panel for Auto door open c...

Page 83: ...is on On some of the new machines this function is a parameter setting Optional Parameter Bit 14 bit 0 Control On Off POWER This is the Power On button Press this button after ON turning on the main c...

Page 84: ...N TION TION TION TION Rev 8 21 01 OKUMA F1 F2 F3 F4 F5 F6 F7 F8 NC STATUS RUN STM SLIDE HOLD PROGRAM STOP ALARM LIMIT A B C D E F G HT H I J K L M N SP O P Q R S T U CTRL V W X Y Z UPPER CASE MODE CAN...

Page 85: ...GENCY STOP 0 2 5 10 30 50 70 80 90 100 110 120 130 150 200 FEED RATE SLIDE JOG I O STOP CW CCW SPINDLE JOG 50 70 80 90 100 110 120 130 150 200 SPINDLE OVERRIDE COOLANT SPINDLE GEAR LOAD MONITOR TOOL I...

Page 86: ...00 INTER LOCK RELEASE ATC APC AAC 1 STEP REVERSE 1 CYCLE START RETURN CYCLE START 1 STEP ADVANC E o RESET A B ADAPT SHOWER ORIENTATIO N CW CCW STOP SPINDLE JOG SPINDLE OVERRIDE 0 04 1 INCH MIN JOG MM...

Page 87: ...PERATION TION TION TION TION Rev 8 21 01 0 1 2 3 4 11 6 Xh 0 1 2 3 4 11 6 HOUR METER Xh EMG STOP RESET READY EMG STOP POWER ON POWER OFF ERROR LIGHT AUTO POWER OFF OPERATION END MODE BZ BUZZER LIGHT P...

Page 88: ...N TION TION Rev 8 21 01 MG MANUAL MANUAL INT INDEX START CW CWW EMG STOP RESET ATC Magazine Operation Panel MANUAL TOOL CHANGE TOOL CHANGE CYCLE TOOL CLAMP TOOL UNCLAMP Manual Tool Change Operation LS...

Page 89: ...the F1 key has to be pressed to get the IN cursor 3 Press the WRITE key 4 Press the CYCLE START button At this time the commands are executed The following is a list of some of the codes that are usef...

Page 90: ...OSP 5000 5020 CONTROL CONSTRUCTION ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501...

Page 91: ......

Page 92: ...the taps on the transformer should be checked before power is supplied to a newly installed machine As a precaution the incoming power and the taps on the transformer should be checked before power i...

Page 93: ...rates a load is put on the incoming power source and the voltage increases slightly This voltage variation has to be less then 6 To determine if the incoming power is sufficient do the following calcu...

Page 94: ...the power gets distributed throughout the system The EC control power source is a step down transformer and a 24 volts DC power supply These two components are usually mounted next to each other The s...

Page 95: ...OP T I ONAL OP T ICAL COMMUNICAT ION I F SP C6 CARD SVP BOARD II D OPUS 5020 POWER SOURCE UNIT OPERATIONAL PANEL TAPE READER PUNCHER VAC III SPINDLE MOTOR DRIVE UNIT SPINDLE MOTOR PULSE HANDLE SENSOR...

Page 96: ...e RHP Rack High Power outputs the following voltages 5V For the integrated circuits IC s in the control 12V For the bubble memory position encoder main spindle pulse generator and the manual pulse gen...

Page 97: ...er very slowly The low voltage detection alarm for the 5 volt supply turns on when approximately 4 6 volts is detected If this alarm occurs proper adjustment cannot be made without disabling this low...

Page 98: ...one error occurred at the same time The CPU stops running ECC Error Error in the main memory of the system DIA Error An error occurred during the self diagnosis function LOOP Error The CPU interrupt...

Page 99: ...and 16 Mbits Up to two bubble cards may be mounted on the MB IIB with a maximum bubble memory capacity of 32 Mbits 4 Mbytes The latest OSP 5020 controls as of 11 93 are now using CMOS memory instead o...

Page 100: ...The active program is run from DRAM on the MC 11 and MC 12 cards These cards are mounted on the MB IIB MC 11 can handle 512 Kbytes of memory while the MC 12 can handle 2 Mbytes of memory Up to three M...

Page 101: ...IA The maximum bubble memory capacity for the MB IIA is 32 Mbits The 1220 card is sometimes referred to as 256 Kbit X 4 A911 1220 128 Kbyte A911 1221 1 Mbit X 1 A911 1222 1 Mbit X 2 A911 1223 1 Mbit X...

Page 102: ...n use any array bubble memory cards Any array of 4 megabit sections and new CMOS memory cards RAM MC1 128 Kbytes of ram MC5 384 Kbytes of ram MC1 II 5M MC9 1M MC5 II 1 5M MC 11 5M MC 12 2M Servo Contr...

Page 103: ...ouch IGF function is purchased This option allows the operator to do some graphics programming at the machine CRP IIC A911 1692 or A911 1693 CRT Processor board This board is used for data communicati...

Page 104: ...ted or commanded axis position data RDIFF is the following error A single SVP board can control two axes For control of more than two axes additional SVP boards and axis cards can be added to the syst...

Page 105: ...ical Control board This board provides the I O information to the main processor MB IIB This board has no CPU It reads the machine status from the limit switches etc and controls the various solenoids...

Page 106: ...F has a buffer memory The data communication between the buffer memory and the EC I O rack is transmitted via the EC bus ECP Card 2 A911 1142 Expansion card This card provides an additional 32 inputs...

Page 107: ...l communications processing CCPC2 Card A911 1596 Signal Converter card This card converts the signal level for RS 232C protocol CCPC3 Card A911 1597 Signal Converter card This card converts the signal...

Page 108: ...ower supply to this board is 5 and 12 volts DC The 8 outputs are fused The solid state relays can handle 100 volts AC O DC1 A911 1272 DC SSR Output board This board was replaced by the O AC1 board Thi...

Page 109: ...fieldnet I O unit Double Column machining centers use an FN card A911 1837 that has more power This extra power is needed to transmit optical pulses through longer fiber optic cables CCOP A911 1841 Co...

Page 110: ...his card is used for turning on LED s and small control relays The communication card CCOP can handle only one FOHT FOPT A911 1844 Fieldnet Output Power Transistor card This card has eight outputs and...

Page 111: ...light source is seen but one of the tips might be damaged causing an alarm To check the tip of a fiber optic cable a low cost slide microscope can be used The following are examples of tips that are e...

Page 112: ...with the 5000 5020 series control system use AC drive technology Some of the early models use DC drive technology with DC brush type motors The following is a description of the servo systems used on...

Page 113: ...th the early 5000M CNC controls have the LDU TR axis drive system The TR stands for Transistor This drive system utilizes PWM technology PWM stands for Pulse Width Modulation The width or duration of...

Page 114: ...re 5 5 The BDU A drive amplifier is composed of three parts base unit BDC board and SVC board The BDU type drives have 3 phase 220 VAC going to their PCB s The BDU A and BDU D use the same type of DCP...

Page 115: ...is still being sup plied to the drives The BLD and BLIID have an indication lamp that remains lit until the capacitor is discharged Wait until this lamp is off before doing any work on the drives The...

Page 116: ...le describes what they mean Description of LED s on SVC 1 board of a BDU D drive amplifier The SVC 2 board has the same LED indicators as the SVC board on a BDU A drive amp Refer to the table for the...

Page 117: ...CB on this power supply only has two LED s on it The following table shows what they mean The following is a description of the LED s found on the BLD A type axis drive amplifier Description of LED s...

Page 118: ...re four settings that should be looked at when a machine is first installed or a D type drive amplifier is replaced These are VLG VNFB VCOM and DA zero The first adjustment that needs to be made on th...

Page 119: ...SVCII board of a BLIID A Description of LED s on BLIID A type drive amplifier LED Color Description PON Green Power is supplied to the control board SVCII OP Yellow Sub Amp Operation of first axis Tu...

Page 120: ...wo big differences about this drive compared to the BLII D type A is the command signal is an analog signal and it comes from the ECP board The SVCII board is the same as the SCVII board on the type A...

Page 121: ...push this discharge button to discharge the capacitors before removing the high voltage wires VH VL This button is labeled Push Switch The BLD and BL IID servo systems do not have a Push Switch they...

Page 122: ...signal from the SVP board The type D drives are referred to as EC controlled axis drives They receive an analog command signal from the ECP board These axis drives are used for positioning the tool m...

Page 123: ...ndle drive servo system SDU stands for Spindle Drive Unit Like the LDU 600 axis drive this is a thyris tor control system that controls the rotational speed of a DC motor by regulating the firing angl...

Page 124: ...Lathes the command signal is generated by the SVP IID board Prior to the SVP IID the command signal was generated by the Timing board TB0 The diagram below depicts this type of servo system Another t...

Page 125: ...command signal origination are very similar This drive has a light blue face plate In 1990 Okuma introduced the VAC II This spindle drive amplifier utilizes fiber optics For any machine using a VAC I...

Page 126: ...U alarm appears on the CRT refer to the appropriate maintenance manual to decipher the alarm condition The VAC has three operation status LED s labeled M1 M2 and M3 and thirteen numbered status LED s...

Page 127: ...only exception It utilizes an optical encoder instead of a resolver for motor speed feedback Some of the Okuma lathes have TCC resolvers which are used to control turret positioning Some of the latest...

Page 128: ...e Every time the output shaft of the absolute position encoder turns 36 there is a 360 offset between the sine signal and the MPR feedback signal This equates to 16384 clock pulses per tenth of a revo...

Page 129: ...stalling the encoder to the motor shaft Check for damage or rust on the taper Check for dirt or foreign substances Check for deformation of motor shaft positioning key slot When installing the encoder...

Page 130: ...degrees depending on the position of the stator which is directly coupled to the output shaft of the MPR As mentioned above the OSP generates a clock signal which it compares to the phase shift betwe...

Page 131: ...his signal The frequency can be calculated by using the following equation f 1 T 1 128 x 10 6 8N 60 where N is the motor speed add in the forward direction and subtract in the reverse direction The mo...

Page 132: ...d mostly for spindle orientation and spindle speed display The resolver in the spindle motor is used to monitor and control the spindle speed On machining centers the pulse generator and the resolver...

Page 133: ...OSP 5000 5020 CONTROL DIAGNOSTICS ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501...

Page 134: ......

Page 135: ...mode also The following is a description of the data shown in the individual menus of the Actual Position mode on a 5000 5020L series control The first line on the CRT will display the operation mode...

Page 136: ...al position value from the zero offset Machine Shows the raw data coming from the absolute position encoder RCON Tool Offset Shows the active tool offset amounts Pitch Shows the pitch error compensati...

Page 137: ...eration method has been selected for the program being executed B Mtd would indicate a larger memory volume was selected BLOCK DATA The block data soft key allows the operator to access the menus that...

Page 138: ...e name The following data is shown on the right side of the screen no matter which menu is selected in the Block Data mode Sr Actual spindle speed Sm Maximum spindle speed fx Feedrate of X axis in mm...

Page 139: ...of Y axis Z Target value of Z axis B Target value of B axis I Programmed I value radius of cut with respect to the X axis J Programmed J value radius of cut with respect to the Y axis K Programmed K v...

Page 140: ...the various axes on the machine The menus are labeled Axis 1 Axis 2 etc A description of the data is provided RDIF Following error of axis drives difference between RCON and RAPA RAPA Actual position...

Page 141: ...o the control rack and these I O s can be viewed in the Extended EC I O menus MDI OPERATION N 0 F3 F7 F8 F1 F2 F6 F5 F4 CHECK DATA UNIT 1 INCH EC INPUT 01 no data bit7 bit6 bit5 bit4 bit3 bit2 bit1 bi...

Page 142: ...are files that are needed when certain options are purchased with the machine Machine Code Only one of these machine codes will be on This code tells the control what type of machine it is controlling...

Page 143: ...nction as the Panel I O s on the lathe controls NC I O s These signals are used by the microprocessor on the main board to communicate with the rest of the machine Because of the excellent diagnostic...

Page 144: ...nu shows the servo related data of the EC controlled axes An example of these types of axes are the APC shifter arm and magazine axes The data displayed is shown below RDIF Difference between RCON and...

Page 145: ...or has entered wrong data This message is displayed on lines 19 to 22 on the CRT and the alarm light does not turn on An error message is usually cleared as soon as another function is performed Machi...

Page 146: ...n in the table below This hex word converts to 11001110 in binary Hexidecimal Octal Binary Decimal 0 0000 0 0 1 1 0001 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0010 0011 0100 0101 0110 0111 1000 1001 1010...

Page 147: ...the RESET button Alarm B 400 899 All commands in the currently executed block are completed Manual operations are possible MDI and Auto operation are not possible Press the RESET button Alarm C 900 99...

Page 148: ...d one for the original MB board The board or card corresponding to the address having been accessed will most likely be faulty If necessary replace the board or card to which the address points The tw...

Page 149: ...6 15 Okuma America Corporation DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS Rev 8 21 01...

Page 150: ...6 16 Okuma America Corporation DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS Rev 8 21 01...

Page 151: ...rd 6 F00000 F7FFFF ECP board II first FFD0A0 FFD0BF Not used area F800000 F87FFF SVP board II first FFD0C0 FFD0FF Main card 14 F88000 F8FFFF SVP board II second FFD100 FFDCFF Not used area F90000 F97F...

Page 152: ...differential transformer FFC000 FFCFFF Operation panel for OSP5000M G FFD0A0 FFDCFF Not used area FFD000 FFDFFF Local I O area FFDD00 FFDE1F Main board II DMA FFE000 FFFFFF Not used area FFDE20 FFDE5...

Page 153: ...Not used area FFDD00 FFDE1F Main board FFBD00 FFBD3F AXIS board FFDE20 FFDE5F Main card 7 FFB040 FFBD4F AXIS card 3 FFDE60 FFDE7F Not used area FFBD50 FFBD5F AXIS card 4 FFDE80 FFDEBF Main card 3 FFB...

Page 154: ...by if any To the right of the alarm number and axis code the alarm level is displayed followed by a message Then to the far right is the alarm code This code is in a hexadecimal format and sometimes...

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Page 157: ...GNOSTICS DIAGNOSTICS DIAGNOSTICS Rev 8 21 01 1 Alarm A Turret index control abnormal A turret 2 F3 F7 F8 F1 F2 F6 F5 F4 MDI OPERATION N 0 260 BLOCK DATA DATA INPUT ACTUAL POSIT SEARCH CHECK DATA Part...

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Page 175: ...OSP 5000 5020 CONTROL PARAMETERS ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501...

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Page 177: ...its and droop data Variable soft limits are used to reduce the cycle time of a workpiece For example in most cases a turret has to be at a soft limit before the control will allow it to index rotate T...

Page 178: ...m Parameter menu have to be reset After the Absolute Position Encoder has been replaced power on an do the following to check or reset the Stroke End Limit parameters 1 Check the RAPA in CHECK DATA si...

Page 179: ...P control card that is sent out with every machine If an encoder has to be changed then these SEL s and zero offsets will have to be reset Rapid This parameter is on the second page of the system para...

Page 180: ...the percentage of the total current capacity of the axis drive amplifier Turret Offset This page of the system parameters shows the offsets of the individual tool stations These parameters allow the...

Page 181: ...y 7 Turn power OFF and back ON 8 Go back to PR ZERO OFFEST for the turret press the F3 CAL function key and enter the angle value which was noted in step 2 then press the WRITE key 9 Press the F5 BACK...

Page 182: ...wered up These parameters are referred to as power reapplication parameters When a power reapplication parameter is changed the CRT will display the message ALARM D W01 power on effective parameter se...

Page 183: ...he amount of travel the axis will overshoot when uni directional positioning is active BACKLASH The backlash compensates for the lost motion on each axis when the axis feed direction is reversed The s...

Page 184: ...APC shifter arm positioning The following MC System Parameter long word parameters are looked at often when troubleshooting an ATC or APC 9 Shows the zero offset of the ATC magazine 41 Shows the zero...

Page 185: ...nd up NC Optional Parameter bit number 17 and up Spindle Control Parameter Input Unit System On this parameter page it is possible to view the unit of measurement being used The unit systems set by th...

Page 186: ...re 2 shows a description the zero offsets on machining centers SETTING ZERO OFFSET Any time an Absolute Position Encoder is replaced a belt is broken or a motor is removed for inspection the zero offs...

Page 187: ...wiveled and becomes a vertical spindle This type of spindle head is used on double column ma chines MCM BARRIER Y Z On horizontal machining centers if both the Y and Z axes enter a certain area at the...

Page 188: ...he ball screws each have their own pitch to pitch errors This set of parameters com pensate for those errors To see the pitch error compensation data for the other axes press the axis change function...

Page 189: ...r screen These counters increment whenever an M02 or M30 are executed During Machine Lock mode these counters do not increment SPINDLE CONTROL PARAMETER These parameters are servo constants and other...

Page 190: ...OSP 5000 5020 CONTROL SOFTWARE ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501...

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Page 197: ...lathes have two system software diskettes The A diskette which has all the NC software and the B diskette which has all the parameter data Most machining centers have three system software diskettes...

Page 198: ...the system software As a precaution all part programs and parameter data should be saved to a diskette before doing any work on a machine This can save hours of down time if the system software has t...

Page 199: ...QUIT LATHES The control should be put in metric mode NC optional parameter bit number three bit zero set to a zero before saving files The date should also be set before saving files so the user will...

Page 200: ...machines These parameters ARE NOT saved during the A TOP file OUTPUT process Therefore it is necessary to record these parameters and input them manually through the control in metric mode LT machine...

Page 201: ...is not necessary to input a message 5 The CRT will display Parameter At the top of the CRT the following menu is displayed Parameter Tape Punch Menu A menu is displayed of the different parameter file...

Page 202: ...sents the upper turret and the N1 is the line number To resolve this alarm the TOP file can be transferred to the BB1 directory to be edited To transfer the UP TOP file follow the same procedure as ab...

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Page 213: ...the cursor appears the load procedure is finished Check MC System Parameter Long Word 9 41 48 Check MC System Parameter Word 1 2 5 6 21 The cable configuration from the OSP control to various peripher...

Page 214: ...ayed When all the files on the A diskette have been loaded the CRT will display Control Floppy Loading Finish or End Control Floppy Loading Wait 7 If there is more than one system software file disket...

Page 215: ...oaded all part programs and parameter data that is not backed up will be erased 1 Power up with E STOP on NOTE MC SYSTEM PARAMETER WORD ONE THROUGH SIX SETTINGS 2 Set the date and time 3 Load Mode ON...

Page 216: ...n Y and press the write key CRT displays Search next Y N 16 Type in Y and press the write key CRT displays MSU Backup OK Y N 17 Type in N and press the write key CRT displays MVU Backup OK Y N 18 Type...

Page 217: ...and press the write key CRT displays This dumps the tool data from the ECP battery backed up area into the MEU file 22 At the cursor type in Q for quit and press the write key When the equal sign app...

Page 218: ...OSP 5000 5020 CONTROL SCHEMATIC SYMBOLS ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501...

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Page 220: ...conductors 1 4 n equals number of conductors in cable 1 5 Shielded cable 3 3 15 36 9 20 QF52 30A 2 Node Not Node 2 1 Connected 2 2 Connected 2 3 Not connected 3 Terminal TB XT XJ Terminal Block Test...

Page 221: ...d Valve Magnetic Brake Magnetic Clutch Magnetic Chuck Electromagnet K614 SOL12A YV4 7 Overload OL OL FR Thermal overload relay Current threshold protective device with time lag action 5 8 B12 W12 8 Tr...

Page 222: ...Reactor Choke Coil 8 1 Fixed 8 2 Adjustable 8 3 Iron core 10 Rectifiers REC REC 9 1 Diode 9 2 Full wave rectifier 9 3 Bridge rectifier CR9 MY 6 11 Motor M G MG TG M Motor M DC Motor Generator G DC Ge...

Page 223: ...stors 11 3 Linear 11 4 Rotary 11 5 Dial Type K102 K102A R 5 13 Fuse F FU 12 1 General 12 2 Enclosed CN2 1 2 3 F1 2 A F1 SCM CN2 2 A 14 Bell BL BL Bell 15 Buzzer BZ BZ Buzzer XBOP4 HA 16 Connector CN S...

Page 224: ...FL HL 19 1 Light Emitting Diode 19 2 Lamp Pilot Lamp 19 3 Fluorescent LED R L E T C P R PLAL T1 A L F L 1 H LO N W X E X B O P1 R 1 21 Ground E FG Earth Frame or Chassis 22 Circuit Breaker CB QF QM 2...

Page 225: ...Limit Switch Micro Switch DS2 TB1 LS1S TB1 C NO SQ9 SQ18 25 Proximity Switch LS SQ Position sensor 25 1 Magnetic Prox Switch NPN LS1C R D B K WH SQ21A 26 Float Switch FS SL Liquid level sensor FSIL T...

Page 226: ...FS Flow switch for air water oil etc TB C O N FS2L 6 8 TB C O N 31 Foot Switch FTS Also labeled Pedal Switch FTS10 NO NO C SF1 XT1 32 Push Button Switch PB PB 32 1 Push Button 32 2 Mushroom Head 32 3...

Page 227: ...Single pole Double throw SA SIL 1 2 SW1 TOGGLE SWITCH 34 Timer Relay Contact TR 34 1 Instantaneous operation in the direction of the arrow Time delay in the opposite direction 34 2 Instant operation...

Page 228: ...Corporation 3 6 TMA CN E0 3 BIT 4 NO 8 3 19 3 20 COM EC IN 01 PIN NO CPU TEMP ALARM LINE NO Name of the EC board Signal Name A306 CN1H 6 60 C CPU OL 5 CN1H TB10 54N C1 ISO24V C1 56N TB10 PAGE LOCATION...

Page 229: ...6E G6E S1 A6 A4 NA 6 NA 4 RU1 1 8 1 8 6 6 1 1 C7 C8 C9 C10 C11 C12 C13 C14 A2 TBPT 3 CN8 H 5 2 1 3 4 TB2 ACN22 PBOFF Push Button RELAY NAME DC24V 5 C1 Location of N O Contacts CONTROL OFF ON A OFF A O...

Page 230: ...n the CPU power supply CR OFF CR ON A606 CR ON A605 CR OFF CR EC 1 CR EC CR ON CR OFF Power OFF Power ON Control ON Control OFF Fig 1 1 DC 24V CONTROL ON Pushbutton CONTROL OFF Pushbutton CR ON CR OFF...

Page 231: ...OSP 5000 5020 CONTROL LATHE SCHEMATICS A40003 ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501...

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