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Factory Training

for

Basic Electrical Maintenance for Okuma

Lathes, Machining Centers and Grinders

with the OSP 5000/5020/500 series control.

Course Code : EL 501
Prerequisite : Basic Electronics
Credits : 0
Course length : 4.5 days
Class Size : 6 persons

COURSE OBJECTIVES - Upon completion, the individual will be proficient in all basic skills
necessary to troubleshoot an electrical side problem on any Okuma CNC machine tool with 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 communicate via the
phone to Okuma service representatives if the need arises for further assistance.

Course emphasis is a blend of classroom instructional theory and “hands on” time spent on the
machine tool.

COURSE REGISTRATION – To obtain program availability dates, please contact Von Pickett
at (803-981-7000) the Institute for Manufacturing Productivity to obtain program availability
dates, or check our website

http://imp.okuma.com

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Содержание OSP 5000

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

Страница 2: ...Intro...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 14: ......

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

Страница 16: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 22: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

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

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

Страница 34: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 49: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 91: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 134: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 155: ...6 21 Okuma America Corporation DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS Rev 8 21 01...

Страница 156: ...6 22 Okuma America Corporation DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS Rev 8 21 01...

Страница 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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Страница 166: ...6 32 Okuma America Corporation Machining Center Machining Center Machining Center Machining Center Machining Center Rev 8 21 01...

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

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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 219: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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Страница 233: ...OSP 5000 5020 CONTROL MACHINING CENTER SCHEMATICS ELECTRICAL MAINTENANCE TRAINING MANUAL EL 501...

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